Biometric and environmental monitoring and control system

ABSTRACT

The present invention is a wearable device for comprehensive bio-monitoring of physiologic metrics to determine metabolic, pulmonary and cardiac function and oxygen saturation measurements from breathing mask apparatuses. The device non-invasively monitors the physiologic profile of the subject, and is capable of detecting physiologic changes, predicting onset of symptoms, and alerting the wearer or another person or system. In some embodiments, the device comprises both a wearable sensor suite and a portable gas composition and flow analysis system. In preferred embodiments, it comprises a miniaturized non-invasive sensor suite for detecting physiologic changes to detect dangerous breathing or other health conditions. The system utilizes advanced fast-response sensors with improved efficiency and lifespan, and provides rapid analysis for substantially real-time monitoring of the subject&#39;s present condition to predict, mitigate and/or prevent the onset of dangerous conditions.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of co-pending U.S. patentapplication Ser. No. 14/510,596 which was filed on Oct. 9, 2014 as acontinuation-in-part of U.S. patent application Ser. No. 13/441,515,which was filed on Apr. 6, 2012, and which claimed priority to U.S.Provisional Patent application Ser. No. 61/889,826, which was filed onOct. 11, 2013, and U.S. Provisional Patent application Ser. No.62/056,035, which was filed on Sep. 26, 2014.

STATEMENT REGARDING FEDERALLY-SPONSORED RESEARCH OR DEVELOPMENT

The U.S. Government has a paid-up license in this invention and theright in limited circumstances to require the patent owner to licenseothers on reasonable terms provided for by the terms of the Phase Igrant number N68335-09-C0294 awarded by the Department of Defense, andPhase II grant number N68335-10-C0548, also awarded by the Department ofDefense.

BACKGROUND OF THE INVENTION 1. Field of the Invention

The present invention relates to monitoring apparatus worn by pilots andother aircrew during flight, divers, first responders, war fighters,climbers, patients and other breathing apparatuses. The presentinvention further relates to physiologic monitoring systems that monitorand predict changes in physiologic states based on altered respiratoryperformance and/or gas conditions indicative of dangerous breathing orother health conditions in pilots and aircrew, divers, first responders,and other subjects using breathing apparatuses. The present inventionfurther relates to warning and control transfer systems that canautomatically generate alarms or warning signals to the wearer or thirdparties, monitor and record physiological data of the wearer andtransmit such data, and/or transfer duties away from debilitatedsubjects.

2. Technical Background

The present invention may be used to monitor, detect, predict ormitigate, the physiologic conditions associated with the wearer causedby hypoxia, fatigue, contaminants, improper breathing techniques,improper breathing gas mixtures, hardware malfunctions, etc. Thesephysiologic conditions or physiologic changes are a major concern forpilots and aircrew, divers, and other subjects operating in conditionswhere breathing conditions may become compromised by environmentalconditions such as altitude, pressure, breathing gas supplies,contamination, or the like. Similarly, other dangerous breathing orother health conditions may occur where the symptoms or outward signs ofthe dangerous conditions appear to be symptomatic of the inconsistenciesin performance of the wearer's life support system.

Hypoxia and similar or related dangerous breathing or other healthconditions may occur as a result of numerous situations or conditions,or physiologic changes in the subject, but most often occurs at highaltitudes, under high gravitational forces (or g-loads) or underwater,or when breathing in a mixture of gases with improper oxygen content.More specifically, generalized hypoxia tends to be caused by low partialpressure of oxygen in the person's blood. However, such hypoxia mayoccur even if the partial pressure of oxygen in the blood is normal. Insuch cases, the hypoxia may be caused by low partial pressure ofatmospheric oxygen (i.e., at high altitude, breathing mixes such as fordivers, or when artificial conditions change the atmospheric breathingmix, such as in a fire or in a sewer). Surgical conditions, such as whenbeing taken off inhaled anesthesia and returning to breathingatmospheric air, may cause hypoxia or other health issues in patients.Other medical conditions, such as sleep apnea or hypopnea, chronicobstructive pulmonary disease, or the like, may also cause hypoxia tooccur.

Symptoms of hypoxia and similar or related dangerous breathing or otherhealth conditions generally depend on the extent and severity of thedeprivation of oxygen to the person's body, or region thereof. Oxygendeficiency in the body will impair the function of the brain and otherorgans. Loss of physical and mental abilities continues to be a concernat high altitudes or under gravitational forces or g-loads, withdelivery of breathing gases, mixing of breathing gases and inrecirculated breathing situations. Symptoms associated with thesenegative physiologic conditions include headaches, nausea, dizziness,fatigue, shortness of breath, tingling, euphoria, confusion, aggression,visual impairment, and loss of situational awareness. More severesymptoms may also occur, and include loss of consciousness, seizures,priapism, coma, or even death. The skin taking on a blue hue alsodenotes severe hypoxia.

Clinically, concerns associated with altitude were reported as early as400 B.C. A cascade of physiologic changes occurs in altitude, none ofwhich are functionally beneficial. For example, pulmonary ventilationincreases, causing a hyperventilation state, affecting carbon dioxideclearing which may lead to respiratory alkalosis altering bicarbonateproduction. Further, ventilation rate and blood pH will increase.Cardiac output (Q) is increased through heart rate compensations. Bloodpressure in the pulmonary arteries increases. The oxygen diffusiongradient is reduced by nearly 50% and hemoglobin saturation is reducedby 5-10%. When these physiologic changes are uncontrolled, breathingdifficulty, mental confusion, poor judgment, loss of musclecoordination, unconsciousness, lack of useful consciousness, dizziness,light-headedness, fatigue, visual impairment, delayed reaction time,nausea, tingling and numbness, and particularly in vehicular (moreparticularly aircraft) travel, G-force induced loss-of-consciousness canresult. Dangerous breathing or other health conditions can result inloss of situational awareness, may impact mission success, and has ledto aircraft and diving mishaps. A complicating factor is that there arewide individual differences in tolerance to acute and chronic exposuresto reduced oxygen environments.

Hypoxia and similar or related dangerous breathing conditions or otherhealth conditions including fatigue induced by long missions, highaltitudes or g-loads has become an especially critical issue with thegrowth and development of aircraft and human flight. Hypoxia and fatigueare notoriously important issue for military fighter pilots. The extremeconditions under which these aircraft and pilots operate give rise to amuch higher than average onset of hypoxic conditions or fatigue whichgreatly endanger the pilot's health and safety. The symptoms of hypoxiaor fatigue are devastating to such a pilot, operating under such extremeconditions. Hypoxia or fatigue under such flight conditions often goesundetected and unrecognized, and has been determined as a significantfactor, or the ultimate cause, of numerous fatal accidents involvingmilitary pilots. Additionally, such accidents cost the governmentmillions to billions of dollars in losses when these aircraft are lost.It clearly becomes important to change the current systems and allow fordetection and early prediction of negative physiologic conditions toprotect the lives of pilots and aircrew from the highly deadly effectsof health issues such as hypoxia or fatigue under such circumstances.The risk of aircrew members experiencing dangerous breathing or otherhealth conditions, one example being hypoxia or fatigue, is present withexposure to high altitude flight, acceleration stress, mountainoperations (helicopter crew), and the like. These negative physiologicenvironments can impair the mission and lead to injury or death. Whilemany of the above-mentioned symptoms may be observable, the exactcondition of generalized hypoxia or fatigue has historically beendifficult to quantify and there is not a gold standard measure orquantitative metric against which hypoxia can be conclusively verifiedin-situ.

The reduction in barometric pressure that occurs at altitude reduces thepartial pressure of oxygen. The lower partial pressure of oxygen limitspulmonary diffusion and oxygen transport to tissue. As result, lessoxygen is delivered to tissue and hypoxia (oxygen deficiency) or fatiguesets in. Pilots and other aircrew members utilize a supplemental oxygensource such as from an on-board oxygen generation system (OBOGS) torectify this issue. Alternatively, and particularly with respect torotorcraft, an OBOGS system referred to as a personal helicopter oxygendelivery system (PHODS) may be employed. However, aviators have beenconcerned with the potential malfunctions of these oxygen generation anddelivery systems. Alternatively, and particularly with respect to diversand patients utilize bottled gases to rectify breathing challenges thatwould benefit from the proposed system.

For the purposes of combating dangerous breathing or other healthconditions for extended missions, the typical high-performance orhigh-altitude aircraft is outfitted with one or more on-board oxygengeneration system (OBOGS) of the type described, for example, by U.S.Pat. Nos. 4,499,914, 4,651,728, 4,783,205, 4,858,606, 4,919,124,4,928,682, 6,923,183, and 6,997,970, all of which are hereinincorporated by reference. A typical OBOGS comprises an apparatus forgenerating breathable oxygen in elevated concentration and an oronasalmask worn by the aircrew member, the mask adapted to sealably fit on theface surrounding the aircrew member's nose and mouth. Together, theOBOGS and the pressurized cabin function to limit adverse environmentalconditions including hypoxic conditions. Current protocol for militaryaircrew/pilots is described as “mask on, always”; however, hypoxiaremains the most frequent hazard in aviation medicine.

Typical oxygen generation systems, which can include OBOGS, operateusing one of several systems utilizing multiple beds or exchange mediacompartments to remove nitrogen from gas to increase the concentrationof oxygen in the gas that is passed through, which becomes breathing gasfor the subject. One such system is known as the Pressure SwingAdsorption (PSA) technique. Depending on the gas that is being removedfrom the supply gas, typically nitrogen, at least two beds or exchangemedia compartments are utilized that contain a specific media ormaterial that is capable of adsorbing the target gas at high pressure.As the supply gas passes through the bed or compartment at a highpressure, the media adsorbs the target gas, and the remaining gas(es)are allowed to pass through, thus becoming breathing gas. When the mediaor material becomes saturated, the system switches to another bed orcompartment, and the saturated one is switched to low pressure whichallows the adsorbed gas to desorb and be purged from the bed orcompartment. The system cycles between the available beds orcompartments while in use, thus always maintaining at least one bed orcompartment functioning to remove the target gas from the supply gas andpass oxygen-rich gas to the subject for breathing.

Another such system utilizes at least a pair of molecular sieves thatoperate to siphon nitrogen gas from the circulating feed air. The sievesremove the nitrogen and allow the remaining air, comprising oxygen andargon, as well as some moisture and contaminants that may be present inthe feed air. These systems generally have at least two or moremolecular sieves that operate individually and cyclically such that onesieve operates at a time until it reaches a certain level of saturationor capacity (i.e., the medium becomes saturated with nitrogen and thefeed air exiting the sieve reaches a predetermined threshold—based ontime—for the percentage of oxygen therein), and then the system switchesto the next sieve while purging the nitrogen from the first sieve.Several problems are known to arise from such a system, however. First,the thresholds are set based on known metabolic and gas law exchanges atground level such that the system is set to alternate between molecularsieves at a given time interval which assumes certain performances whilein flight. In other words, based on known measurements and conditions atground level, the system is assumed to create the desired oxygenconcentration in the produced gas after a given amount of time which mayalso presume a given altitude. This system fails to take into accountthe dynamic changes that occur at high altitudes which may be influencedby changes in temperature, presence of moisture which tends to clump inthe medium contained in the sieves thus decreasing their efficiency, andfreezing that may occur of the moisture present, just to name a few.OBOGS systems presently do not contain any system or device for actuallymeasuring the gas concentrations with sufficient response time tomanipulate the feed air or the produced gas, instead operating only onthis timed cycle, which leads to an inefficient system that never reallymeasures or knows the concentration of oxygen being provided to thesubject. Further, changes in molecular sieve and oxygen generationsystem technology may lead to molecular sieves that have a moretransient output. This rapidly changing output creates a morecomplicated control problem as it requires a fast response sensor thatcan track with the output. In order to take advantage of the advances inthe molecular sieves, a more sophisticated feedback sensor and controlsystem for the OBOGS will be needed.

Systems that employ OBOGS typically utilize plenums as well as at leastone, then preferably several, oxygen reserve systems that can provideoxygen to the subject in the event that the subject is not receivingenough oxygen to support healthy breathing conditions. Emergency OxygenSystems (EOS) are generally reserves of pure oxygen, either in gas orliquid form and mounted on the pilot's seat, which can be called upon ondemand by the subject when necessary. Typically, the EOS is activatedwhen the subject activates an emergency lever or handle that opens theEOS system to begin delivering a bolus of pure oxygen to the subject.EOSs generally continue to provide this pure oxygen until the supply isexhausted, i.e., they are not able to be turned on and off. BackupOxygen Systems (BOS) are another form of backup oxygen systems designedto aid in providing the pilot sufficient breathing gases. More recently,Automated Backup Oxygen Systems (ABOS) are designed to automaticallykick in and provide oxygen when needed without requiring the subject toactivate the system. BOS and/or ABOS are generally part of the OBOGSand, similar to EOS, comprise a canister containing a finite volume ofoxygen, again in either gas or liquid form. Both gas and liquid oxygenreserves have pros and cons. Gaseous oxygen systems allow for readilyusable oxygen to be supplied substantially more quickly to the subjectwhen needed, but require large tanks that take up a lot of physicalspace in order to carry large enough volumes of oxygen for extended use.Liquid oxygen systems require less space to carry larger volumes ofoxygen, and thus can provide more oxygen for longer periods ofrequirement, but the conversion from liquid oxygen to breathable gasoxygen requires more equipment and thus more opportunities for failure.Further, current EOS, BOS, and ABOS systems are generally not monitoredfor volume or flow rate, but rather are just activated and provideoxygen until their reserves are depleted. Thus, it is an object of thepresent invention to provide various levels of sensors to monitor thenumerous oxygen and gas parameters of such systems.

Several factors have been associated with dangerous breathingenvironments, some of which are physiologic, and others being associatedwith equipment failure. It is important in the context of the presentinvention to identify and understand many of those geneses. Mechanicalcauses may include a contaminated OBOGS (smoke/fumes), a leaking orclogged breathing hose, a poor seal around the face of the oronasalmask, OBOGS malfunction (which could be caused by improper maintenanceor battle damage), and/or altered cabin pressure (which again couldresult from battle damage). Physiological causes may include anemia,medications, blood loss, fatigue, dehydration, fever, and sleepdeprivation. Environment causes may include temperature extremes andanxiety/stress. Other known contributing causes of negative healthconditions include alcohol use, drug use, and disease.

Cases of dangerous breathing or other health conditions, in pilots areoften unreported. Currently, the only warning a pilot typically receivesis an OBOGS failure light or their own recognition of the symptoms fromtraining. In both of these cases, the pilot's faculties are on their wayto being impaired if they are not already impaired. Due to the insidiousnature of dangerous breathing or other health conditions, the use ofOBOGS instead of gaseous supplies, and the potential for oxygen maskleakage or improper mask use, a need exists for a personal physiologicmonitoring system and/or status monitor that can detect physiologicchanges, predict the onset of symptoms, alert the subject, and ideallyrectify the problem. It is an object of the present invention to providethese features and advantages. It is thus an object of the presentinvention to address these issues in pilot and aircrew physiologicalmonitoring and to provide a system capable of detecting or predictingdangerous breathing or other health conditions and in some cases makingadjustments to remove the conditions.

Another major area of interest for identifying and predicting dangerousbreathing or other health conditions is that of divers, particularlymilitary and combat divers. Such divers generally utilizeclosed-circulation systems which recirculate breathing gas mixes inorder to avoid expiration of gases into the water, which would causebubbles and thus might give away a diver's location. In manycircumstances, a group of divers are deployed in various locations,being deposited by a diver delivery vehicle, and using such arecirculated breathing system to sustain their breathing. However, thesymptoms of various dangerous breathing or other health conditions mayprevent a diver from being able to perform or respond to conditions, tocommunicate with other divers or the dive master, or to be found by thedelivery vehicle when the mission is over. Dangerous breathing or otherhealth conditions may so disorient a diver that he or she is unable toascertain the circumstances or to swim, thus leading to greatlyincreased risks of injury, being lost, or death. Much like pilots above,changing the current diver monitoring systems will help save the livesof numerous divers from the deadly effects of many dangerous breathingor other health conditions. It is thus an object of the presentinvention to address these issues in physiological monitoring of divers,and to provide a system capable of detecting or predicting dangerousbreathing or other health conditions for use with many types ofunderwater breathing apparatuses including, but not limited to militaryand combat diver breathing systems, commercial diver breathing systems,recreational and personal diver breathing systems, and the like.

These same concerns arise for other critical response personnel, forexample, firefighters and emergency first responders. Firefighters inparticular are often subjected to harsh conditions where breathingconditions are harsh and hypoxic that require the use of supplementaloxygen, respirators, self-contained breathing apparatus (SCBA), etc.Sensor systems for detection and prediction of dangerous breathing orother health conditions will similarly benefit firefighters and othersuch first responders who are asked to enter such harsh conditions attheir own peril and who may be subjected to great danger if dangerousbreathing or other health conditions were to set in, rendering theresponder unconscious or incapacitated in some way. Further, thesehazardous environments which require the use of breathing aids such asthe SCBA do not provide the wearer of external environmental conditions.Thus, it is thus an object of the present invention to address theseissues in physiological monitoring of other critical and first responseteams, and to provide a system capable of detecting or predictingdangerous breathing or other health conditions.

Another major area of interest is for monitoring and determining,in-situ, the amount of breathing gases needed for military freefallapplications such as High Altitude High Opening (HAHO), High AltitudeLow Opening (HALO) jumpers and other military skydivers. Theseapplications typically require the diver to carry an oxygen deliverysystem such as an oxygen tank that provides breath-by-breath oxygen viaa mask. The preferred embodiment will integrate the sensing andmonitoring system within this mask and administer appropriate amounts ofoxygen throughout the mission based on each individual's physiologicdemand and not based on a generic algorithm. In doing so, the wearer maybe able to extend the mission through consuming oxygen on demand orutilize a smaller oxygen tank for similar duration missions.

Additionally, it is envisioned that other breathing mask andnon-breathing mask environments such as with the use of an oronasalcannula, can benefit from a sensor system such as the present invention.Other military and similar scenarios include helicopter pilots, such asthose operating in mountain terrain, and soldiers operating at highaltitudes. Further, the present invention is envisioned as being usablewith systems such as sleep masks, anesthesia delivery systems, oxygenmasks and the like. All systems utilizing a breathing mask whereinadditional measurements and metrics provided by the present inventioncan help detect or predict the onset of dangerous health conditions.

In identifying or predicting dangerous breathing or other healthconditions, the problem arises in that many dangerous breathing or otherhealth conditions, for example hypoxia, are highly personalizedresponses to breathing conditions. There are no bright line markers orlevels, which indicate at what point a person will become negativelyimpacted by their environment. Each person responds differently tobreathing conditions, and each person will thus experience variousdangerous breathing or other health conditions at a different rate andunder different conditions. Traditional methods of monitoring andidentifying hypoxia and other conditions have many shortfalls. The mostcommon and generally utilized method of such monitoring is measuringoxygen saturation (SpO₂) of the blood by means of a pulse oximetermeasurement. Research and trials have shown that oxygen saturation,though useful, is not accurate in identifying individual measures ofhypoxia, and predicting the onset of hypoxia. Further, oxygen saturationis significantly influenced by the presence of CO in the blood whichdetrimentally changes the appearance and functionality of the red bloodcells. Because the onset of negative physiologic conditions such ashypoxia may only be detectable or predictable from a combination of awide variety of factors, it is important that a physiological monitoringsystem be capable of detecting and measuring multiple types andvarieties of conditions, and combinations thereof, and in using thosemeasurements to determine the individualized response to the givenconditions. It is thus an object of the present invention to be able todetect and measure a wide variety of factors, which contribute tophysiologic status ergo dangerous breathing or other health conditions,and to calculate still others physiologic measures, allowing the systemto accurately identify and predict the onset of such conditions.

It is a main object of the present invention to provide a system for usein a variety of applications where OBOGS or PHODS are employed todeliver oxygen or a breathing mix of gases to the subject. It isfurther, generally an object of the present invention to provide such asystem for monitoring the subject's physiological condition andbreathing conditions, detecting or predicting dangerous physiologicaland breathing conditions, for example to detect or predict the onset ofhypoxic conditions, to mitigate the onset of such dangerous breathing orother health conditions, and further to provide an alert or warningsystem to help the subject or a third party take further precautionaryor counter measures to prevent, mitigate, or treat such dangerousbreathing or other health conditions. Similarly, other dangerousbreathing or other health conditions may occur where the symptoms oroutward signs of the dangerous condition appear to be symptomatic ofclassical hypoxia, but may not be. For the purposes of this application,the system is designed to be used for detecting, predicting, mitigating,warning, and/or preventing the onset of dangerous breathing or otherhealth conditions. In other words, most generally, the present inventionis intended to provide a system and method for monitoring the breathinggases and to identify physiological changes and/or status of the user orsubject. More specifically, the system is intended to use thephysiologic changes or status changes to detect predict, mitigate, warnand or prevent of the onset of dangerous breathing or other healthconditions.

No sensor suite is presently available to monitor, detect and/orpreemptively warn the subject of such dangerous breathing or otherhealth conditions. Therefore, it is further an object of the presentinvention to provide a sensor suite capable of providing aneasy-to-interpret warning signal indicating a physiologic change thatoccurs prior to the potential onset of dangerous breathing or otherhealth conditions, and to non-invasively monitor the breathing gasesprovided to and physiologic profile of the pilot, diver, or othersubject. The measures will be used to generate alarms or warnings forthe wearer or other members of the team, such as other pilots or divers,a central hub such as a home base, or a dive master, or another remotemonitoring station, based on detectable changes in breathing gases orphysiological changes.

It is further an object of the present invention to provide aminiaturized non-invasive sensor suite for collecting physiologicmeasurements to detect hypoxic state. Miniaturization of the sensors isan important feature because it allows for the sensors to be placed in agreater range of devices and places in those devices. Additionally,miniaturization allows for an increased number of sensors to be includedin a single system, thus greatly increasing the number of individual andcombinations of measurements that can be obtained from the wearer.

It is further an object of the present invention to provide a compact,portable, vehicle independent system that is non-encumbering to thesubject. The system should be able to be retrofitted onto existingbreathing mask systems with minimal adaptation or additional equipment.The system should be relatively self-contained, in that the sensors andprocessor of the system should be located in close proximity to eachother, and preferably all contained within the wearable system placed onthe subject.

It is further an object of the present invention to provide aphysiologic monitoring platform that employs both diagnostic andprognostic capabilities. The system should be able to not only detect oridentify when dangerous breathing or other health conditions arepresently occurring, but should also be able to substantially predictthe onset of such conditions in time to provide an adequate warning tothe subject or an exterior monitoring station or team member to try andinitialize preventative or corrective procedures.

It is further an object of the present invention to provide a compact,portable system integrated into a breathing mask that is non-encumberingto the subject. The system should be relatively self-contained, in thatthe sensors and processor of the system should be located in closeproximity to each other, and preferably all contained within thewearable system placed on the subject. The system should be coupled withthe breathing gas supply system and should supply oxygen to the wearerbased on physiologic need instead upon a timed schedule.

It is further an object of the present invention to provide robust,rapid sensors and sensing of gases, particularly oxygen, in all stagesof the life support system. These sensors are intended to monitor,detect and/or provide feedback with respect to the operation,performance, condition, etc. of the life support system which providesbreathing gasses to the subject such as a pilot, skydiver, underwaterdiver, first responder, and more. Therefore, it is further an object ofthe present invention to provide a sensor suite capable of monitoringand assessing the gasses supplied and operation of the oxygen generationsystems such as an OBOGs or gasses circulating within a rebreather. Thesystem should be able to monitor and determine the gas percentagesand/or partial pressures of various gases at numerous stages of theprocess including in the OBOGS and reserve systems (BOS, ABOS and EOS),in flow and in-line with the inhaled-side gas flow of the breathing mixand the exhaled side of the subject's breathing, or in integratedbreathing mask systems with rapid sensors comprised in the mask toenable functionality of the system. More specifically, these sensorsuites are intended to provide closed loop feedback to the life supportsystem providing breathing gasses to the subject. In doing so, thesesensor suites will assess the functionality and performance of theselife support systems and will maintain or improve the operation of suchsystems with respect to the ability to provide breathable air to thesubject. Potential applications of the present invention include use byNavy, Air Force, and Marine aircrew members, use by Special Forces andother personnel, in mountainous terrain operations, use in performanceevaluations and training exercises where the effects of oxygendeprivation are a potential issue, use by military divers, especiallythose who use rebreather apparatus, potentially exposing them to thedangers of dangerous breathing or other health conditions, use bymilitary skydivers (especially HAHO and HALO jumpers), mountaineeringand high altitude sports, search and rescue personnel and other firstresponders (especially fire fighters), mining operations, and clinicalapplications where breathing masks as utilized such as anesthesia,oxygen or sleep masks, and other underwater applications such asunderwater construction or farming, recreational or commercial diving,and the like using either rebreathing or non-rebreather systems.

BRIEF SUMMARY OF THE INVENTION

The present invention relates to monitoring apparatus worn by pilots andother aircrew during air flight, underwater divers, skydivers, firstresponders such as firemen and rescue personnel, patients and others whomay benefit from breathing mask apparatuses (“subjects”). Further thepresent invention relates to monitoring systems that integrates with asystem that provides, processes or generates breathable air for thereferenced subjects. The system of the present invention is versatile,small, low-power, minimally invasive, and able to address the monitoringrequirements of numerous conditions, scenarios, and settings. The systemis capable of conveniently acquiring status of breathing gasses and/oracquiring physiologic metrics and biometric data of a subject that willdetect and preferably mitigate the risks and hazards associated with forexample high-altitude operations, high g-forces, underwater diving,self-contained breathing apparatuses, high-pressure, low-oxygen, andcontaminated air environments among its many applications. The system iscapable of acquiring breathing gas conditions, status of the breathinggas generation system, physiological data and/or ambient metrics fromsubjects that will mitigate the risks and hazards associated with forexample hypoxic conditions, hypothermic conditions, hyperventilation,fatigue, and other conditions that may put the subject physically atrisk. The present invention also includes a method of monitoring thephysiological condition of subjects as well as a method of adjusting thedelivery of gases, medications, chemicals and other physical treatmentor stimulation to the subjects. Further, the present invention includesa system for alerting the subject/wearer of the device or a third partyof such dangerous breathing or other health conditions, and/orimplementing an automated or semi-automated system for closed-loop orsemi-closed loop control of the breathing mix of gases. A furtherembodiment of the present invention will monitor, and/or alertindividuals to the operation, performance and condition of the lifesupport hardware.

The systems, devices, and methods of the present invention are designedfor use in operations of many varieties. Preferably, the system may beused, or adapted for use, with any vehicle, suit or clothing or wearableapparatus, or other such environments where breathing masks are, or maybe used. For example, the system is designed for use in vehicles wherethe pilot, sky diver, underwater driver, and/or other crew members orpassengers may use breathing masks, such as in fixed wing aircraft,rotorcraft, underwater vehicles, land or ground vehicles, spacecraft,and the like. Further, the system is designed to be used withman-mounted or wearable suits or apparatuses utilizing breathing masks,such as firefighters, skydivers, combat, recreational, salvage, and allvarieties of underwater divers, first responders, and the like.Additionally, the system may be used with non-breathing mask apparatusessuch as those breathing systems utilizing nasal cannula or other suchbreathing gas delivery systems.

The systems, devices, and methods of the present invention are generallydesigned to be used with life support systems that utilize a mechanismto generate or provide breathable air to the subject such as an on boardoxygen generation systems (OBOGS) and personal helicopter oxygendelivery systems (PHODS) or bottled gases to generate and deliver oxygenand/or a breathing mix of gases to the subject. PHODS are typicallyman-mounted systems employed specifically in rotorcraft that thehelicopter pilot, flight crew, and or passengers wear while therotorcraft is in flight, but remains with the subject when he or shedeparts the rotorcraft. Typically, the main difference between OBOGS andPHODS is that OBOGS are generally used with systems that employbreathing mask apparatuses that typically cover and enclose thesubject's mouth and nose, whereas PHODS tend to work with systems thatemploy a partial mask, or no mask, and nasal cannula for deliveringoxygen or breathing mix of gases to the subject. Nasal cannula are notexclusive to oxygen or breathing mix delivery systems for rotorcraft,but are also used in various ground applications such as in hospitals,medical transport, and field deployment. For purposes of thisapplication, both OBOGS and PHODS are used interchangeably, and bothrepresent the oxygen delivery system used in conjunction with devicesand sensors of the present invention. Thus, the systems, devices, andmethods, and particularly the sensors, of the present invention aredesigned to be either interchangeable between breathing mask and nasalcannula breathing systems, or are adapted to be used with one or theother.

The system collects ambient, environmental, system and physiologicaldata and respiratory gas profiles to track the overall condition of thesubject. Ambient, environmental, and system data may include, but is notlimited to, pressures, temperatures, g-force, altitude, depth, and thelike. Physiological data such as the subject's ventilation, fractionalconcentration of expired oxygen (FEO₂), fractional concentration ofexpired carbon dioxide (FECO₂), breath-by-breath volume (BV), breathfrequency (BF), electrocardiogram (ECG or EKG), heart rate, heart ratevariability, axillary skin temperature, galvanic skin response, andblood oxygen saturation (SpO₂) are among the many types of data,profiles and metrics that can be acquired alone or in combination by thevarious embodiments of the present invention. When complete, the dataacquired from the system will provide warnings to the subject or othersabout the onset of negative health conditions including but not limitedto hypoxic, hypothermic or other at risk conditions—or can be used incombination with a controller or processor to adjust some condition ofthe subject including but not limited to the delivery of gases such asoxygen to the subject, or to a separate oxygen or breathing as mixdelivery system. Additionally, the data may be used to assess thebreathing gasses provided to the subject or for recording, tracking andidentifying events from the system to evaluate its status and todetermine the potential for future service, repair or replacement.

Various embodiments of the system of the present invention use a smallor portable sensor unit or units (sometimes referred to as PortableDigital Analysis Unit(s) or PDAUs) capable of providing time basedmeasurements of a subject's ventilation, inhaled breath (e.g., flow, gasconcentrations, and the like), oxygen uptake (O₂), carbon dioxide (CO₂)output, oxygen remaining in expired breath—at rest, during exercise,under various field environments and conditions—particularly extremeenvironments and conditions, and heart rate. Various embodiments of thissystem are differentiated from traditional systems such as for examplespirometers which are bulky and cumbersome, and which are typicallyhard-wired to a data acquisition system, and much too finicky andfragile for use outside a controlled laboratory setting. Preferably, theelectronic components of the present invention are sufficientlyminimized so as to decrease the size and weight of the PDAU so that iteasier to carry and less cumbersome to the subject or user.Additionally, the electronic components are sufficiently devised toeffectively operate under varying temperature, pressures, flow rates,and humidity conditions typical of these environments.

Various embodiments further include a breathing mask or system with oneor more of the sensors mentioned herein such as gas sensors, organiccompound (volatile or non-volatile) sensors, flow sensors, temperaturesensors, heat flux sensors, respiration sensors, pressure sensors,physiological electrodes such as ECG, EMG, EOG, and EEG, a pulseoximeter, body conductance sensors, body resistance sensors,accelerometers, gyroscopes, body potential sensors, blood pressuresensors, impedance sensors, microphones, body and blood chemistrysensors, galvanic skin sensor and the like, which can be incorporatedfor example into or on a mask, a gas intake port or tube, the subject'sclothing or equipment, or expired air port or tube as well depending onthe function of the sensor and the data needs. The sensors in the maskor system can be tethered wirelessly or by electrical connection. Thewireless tethering can be through radio frequency, optical link,acoustics and the like. The sensor signals are transmitted through anappropriate link to an electronic data acquisition or controls box orother subsystem that might in certain embodiments contain either a smallon-board processor and/or other electronic components for not onlyreceiving the sensor(s) signal, but also for possibly filtering,digitizing, converting, calculating and the like of the signal and datainto information related to the subject's physiological condition and incertain embodiments using that information or data to control thedelivery of gases, medication, and/or other physical stimulation to thesubject.

The monitoring apparatus is preferably a small, wearable systemcontaining at least one sensor for detecting and measuring particularconditions of the subject's breathing. The sensors are preferablyintegrated into a breathing mask or nasal cannula breathing system andare therefore external to the subject's body, thus making the presentinvention a non-invasive or minimally invasive system. The sensors arepreferably miniaturized so as to fit into breathing mask or nasalcannula systems. Also preferably, the system may be designed to beeasily retrofitted or attached onto existing breathing mask systems byattachment means such as threads, clamps, snaps, pressfit connectors,lock rings, set screws, and the like, thus minimizing the amount ofhardware and equipment actually necessary to implement the presentinvention, while maximizing the utility of the system across multipleplatforms. Alternatively, some embodiments especially for sky divers mayutilize sensors that are implanted directly into or integrated with abreathing mask system. For example, a sensor, or sensor wires orcontacts, may be inserted directly through the breathing mask system(e.g., by punching a hole through the mask system, then sealing thewhole around the sensor, or sensor leads or contacts to maintain anairtight seal) or designing the mask around the sensors. Otherembodiments, particularly ground applications such as stationary medicalcare facilities (e.g., hospitals, forward/field care units, and thelike) and medical transport (e.g., ambulance, helicopter), may includesensors that are attached, integrated, or otherwise installed directlyinto medical hoses and tubing. The majority of embodiments of thepresent invention are specifically designed to include sensors that aremodular in nature and can be easily attached, detached, added, andreplaced in the event of failure. The sensors may further be able to beadded in series with each other. The present invention is designed to beused or adapted to be used on any of these environments to help monitor,detect, predict, mitigate and or prevent dangerous breathing or otherhealth conditions of any type of user, including both children andadults.

In order to measure the breathing conditions and to identify and predictthe onset or presence of various physical conditions of the subjectincluding but not limited to hypoxia, hypothermia, hypo- andhyperventilation, G-LOC, A-LOC, atelectasis, metabolic cost, fatigue,physiological changes, work of breathing (WOB), tidal volume, oxygenconsumption (VO₂), carbon dioxide production or exhalation (VCO₂),presence of contaminants, and the like, sensors are required which havethe capability to measure and detect numerous conditions surrounding thesubject. Such conditions include physiological signals from the personwearing the device, as well as environmental and ambient conditions, andstatus or conditions of the system, and signals related to thoseconditions. For example, sensors for detection and measurement of allambient air gases may be used to determine the conditions of bothinhaled and exhaled breaths of the subject. Most importantly, sensorsfor detection and measurement of oxygen and carbon dioxide are usefulfor dangerous breathing or other health conditions determination, butsensors for many other gases may be included. Sensors for detection ofother surrounding conditions may be included as well, such as fortemperature of the inhaled and/or exhaled breaths, ambient temperature,pressure sensors for measuring for ambient (cabin) pressure, ambientpressure (non-enclosed environments such as divers, man-mounted systems,ground applications, and the like), in-mask pressure, vest pressure, andthe like, flow sensors for measuring gas flow either pre- orpost-inhalation, g-force sensors, or sensors for detection of carbonmonoxide (CO) and volatile organic compounds (e.g., jet fuel),hydrocarbons, and other such contaminants which may be present and havean adverse effect on a person's breathing and oxygen levels. Furtherembodiments include monitoring the gases and its flow rates, pressuresand temperatures being delivered to the subject. This embodiment mayinclude an integrated PDAU to aid in the integration onto various lifesupport platforms.

Generally, some embodiments of the present invention involve a portablesensor-suite that is capable of being mounted to a subject, thesubject's clothing or gear, or a vehicle in which the subject islocated. Preferably, the sensor suite is able to acquire measurementsand signals that either measure or can be used to calculate variousmetrics regarding the subject's condition, particularly surround thesubject's breathing conditions, including, but not limited to, work ofbreathing, oxygen consumption (VO₂), carbon dioxide production (VCO₂),metabolic cost, atelectasis and the impact thereof, fatigue,physiological changes and numerous other metrics while the subject isunder extreme conditions such as a pilot or a diver in their arena ofwork. The various sensors described herein allow the system to obtainall of these metrics, and can combine them with gas quality data of thebreathing gas mix, thus providing a robust measurement matrix includingboth system and subject conditions and providing all the measurementstypically available separately through spirometry and metabolicmeasurements.

Preferably, the sensors used in the various embodiments of the presentinvention are tolerant to extreme conditions and rapid changes inconditions such as pressure, temperature and humidity. The sensor moduleof the present invention can be used to measure the various individualsignals and conditions discussed throughout, but can further be used forenvironmental conditions such as to assess the fit of a breathing maskthe subject is wearing and to determine if the subject is wearing themask, to determine causes or sources of problems such as leaks in themask, disconnected tubes, or the like. In other words, the sensors arenot merely for measuring specific conditions at specific locations, butrather by fusing the data from the multiple sensors at variouslocations, the overall system performance and conditions can bemonitored substantially continuously.

Various embodiments of the present invention may also include a thirdparty monitoring system of the subject's physiological condition and/orvarious control and actuations systems including algorithms, which areused to change the subject's environment to improve the subject'sphysiological condition, to actively warn the subject, to reposition thesubject's environment, or to adjust the subject's hardware.

Measurements and signals from the sensors described herein are furtherused to calculate other environmental and physiological conditions ofand surrounding the subject. The sensor measurements and subsequentalgorithmic calculations are used to monitor the subject's overallcondition, to detect or predict the onset of dangerous breathing orother health conditions, to mitigate the onset or severity of thosedangerous breathing or other health conditions and their symptoms, andto activate an alert or warning system which notifies the subject or athird party who may then initiate action to further prevent, mitigate,or treat the dangerous conditions and symptoms.

Other embodiments may include many other sensors besides and/orincluding the portable sensor suite that can be mounted to the subject,oxygen generation system or vehicle, such as contamination sensors,sensors for measuring other gases (e.g., carbon monoxide), or the like.Portable sensors suites include the benefit of being vehicle orenvironment independent meaning that they can be utilized betweennumerous such vehicles or environments depending on the subject's need.Many embodiments will employ sensors throughout the entire breathingsystem and environment surround the subject, including a vehicle, suchas an aircraft or underwater vehicle. These sensors may be utilized tocomprise Breathing Air Monitoring Systems (BAMS) which may includesensors upstream from the subject (e.g., on OBOGS, EOS, BOS and/or ABOSsystems, plenums, and regulators) to monitor the generation and flow ofbreathing gases. Preferably these sensors are on the subject, attachedto, and/or integrated with the subject's breathing gear (e.g., in theCRU, breathing tube, the subject's mask, and the like), and downstreamfrom the subject (e.g., exhaled side of the subject's mask, gascirculation and recirculation systems, and the like), to monitor allstages of the breathing gas providing process.

BAMS preferably operate in real-time to monitor the breathing gasesprovided to the subject and to assess and determine the quality andcontent of such breathing gases to ensure the subject is receiving adesired mix and is breathing properly. BAMS may include any type andcombination of sensors described herein, and preferably comprise atleast an oxygen sensor and a flow sensor, though may greatly benefitfrom temperature sensors, pressure sensors, carbon monoxide sensors,carbon dioxide sensors, humidity sensors, contaminant sensors, and thelike. Systems with upstream sensors allow for monitoring and control ofthe breathing gas (particularly oxygen) generation systems to ensurethat an appropriate mix of breathing gases is being provided to thesubject. The selected sensors may also provide the system with theability to provide closed-loop feedback to the oxygen generation systemsuch as an OBOGS system to control the output and mix of gases. Allsensors of the system are preferably rapid-response sensors capable ofobtaining measurements very quickly and accurately. The preferred BAMSembodiments may be after-market devices that can attach to existingequipment in breathing systems, or may be an integrated component, suchas a CRU comprising the preferred sensors.

Placing rapid response sensors, and particularly fast response oxygensensors throughout the system from gas generation (e.g., at the OBOGS),to after exhalation allows the system to differentiate between problemsthat occur at different locations in the line. The fast response sensorsfurther alleviate issues that arise from the mixing of inhaled andexhaled gases, and particularly the measurement of each of inhaled andexhaled breaths separately. The sensors preferably are fast enough tomeasure each type of breath as it occurs and before the inhaled andexhaled gases can mix. Differentiating between oxygen generation issuesand other issues located further downstream in the breathing gas linecan help determine whether the subject is receiving the appropriate mixof breathing gases, and can allow the system to provide a signal orwarning to the subject when a problem occurs to activate a mitigatingsolution to counteract the improper breathing conditions. Thus, thesubject may manually initiate a mitigating process, such as activatingthe BOS or EOS, or the system may automatically activate a mitigationtechnique such as providing pure oxygen with the EOS or ABOS. Continuousmonitoring of the various systems and subsystems (e.g., OBOGS) furtherallows the system to continually assess their performance and determinewhen maintenance may be required.

Aside from the breathing pathway sensors, additional sensors may beutilized to monitor the conditions of other components, such as theprocessing unit, such as the PDAU described herein. Sensors in the PDAUcan be used to monitor the environmental conditions surrounding thesubject and determine when environmental stresses such as pressure,temperature, light levels, g-levels, acceleration, noise or sound,vibration, humidity and the like. Generally, the PDAUs described hereinare also independent and portable such that they can be used acrossnumerous vehicles and environments as necessary.

Various features of the present invention are described within thispatent application. It is understood that the present invention can beconsidered to embody many of these features in various combinationswithout departing from the spirit of the present invention. A smallnumber of examples of the present invention are described in thefollowing embodiments. One embodiment of the present invention includesa breathing mask sensor system for identifying or predicting dangeroushealth conditions comprising at least one sensor having a signal relatedto an in-breath partial pressure of oxygen from exhaled breath of asubject, and a processor for receiving the signal, the processor furthercomprising an algorithm, wherein the algorithm is for substantiallyidentifying or predicting a mass of oxygen absorbed per breath based atleast in part on the signal related to the partial pressure of oxygenfrom exhaled breath of the subject.

One embodiment of the present invention includes a breathing mask sensorsystem for identifying or predicting dangerous health conditionscomprising at least one sensor having a signal related to an in-breathpartial pressure of carbon dioxide from exhaled breath of a subject, anda processor for receiving the signal, the processor further comprisingan algorithm, wherein the algorithm is for substantially identifying orpredicting a mass of oxygen absorbed per breath based at least in parton the signal related to the partial pressure of carbon dioxide fromexhaled breath of the subject.

Yet another embodiment of the present invention includes a breathingmask sensor system for identifying or predicting dangerous healthconditions comprising at least one sensor having a signal related to anin-breath partial pressure of oxygen from inhaled breath of a subject,air flow, and rest rate, at least one sensor having a signal related toan in-breath partial pressure of oxygen from exhaled breath of asubject, and a processor for receiving the signals, the processorfurther comprising an algorithm, wherein the algorithm is forsubstantially identifying or predicting a mass of oxygen absorbed perbreath based at least in part on the signal related to the partialpressure of oxygen from inhaled and exhaled breath of the subject.

Still another embodiment of the present invention includes a breathingmask sensor system for identifying or predicting dangerous healthconditions comprising at least one sensor having a signal related to anin-breath partial pressure of oxygen from inhaled or exhaled breath of asubject, and a processor for receiving the signal, the processor furthercomprising an algorithm, wherein the algorithm is for substantiallyidentifying or predicting oxygen saturation in blood based at least inpart on the signal related to the partial pressure of oxygen fromexhaled breath of the subject.

Another embodiment of the present invention includes a breathing masksensor system for identifying or predicting dangerous health conditionscomprising at least one sensor having a signal related to temperature ofexhaled breath of a subject, and a processor for receiving the signal,the processor further comprising an algorithm, wherein the algorithm isfor substantially identifying or predicting the subject's core bodytemperature based at least in part on the signal related to temperatureof exhaled breath of the subject.

Yet another embodiment of the present invention includes a breathingmask sensor system for identifying or predicting dangerous healthconditions comprising at least one sensor having a signal related to anin-breath partial pressure of carbon dioxide from exhaled breath of asubject, and a processor for receiving the signal, the processor furthercomprising an algorithm, wherein the algorithm is for substantiallyidentifying or predicting oxygen saturation in blood based at least inpart on the signal related to the partial pressure of carbon dioxidefrom exhaled breath of the subject.

Still another embodiment of the present invention includes a breathingmask sensor system for identifying or predicting dangerous healthconditions comprising at least one sensor having a signal relating to ameasure of volatile organic compounds contained in an air flow, and aprocessor for receiving the signal, the processor further comprising analgorithm, wherein the algorithm is for substantially identifying orpredicting a toxicity or danger level of said volatile organiccompounds.

Still yet another embodiment of the present invention includes abreathing mask sensor system for identifying or predicting dangeroushealth conditions comprising at least one sensor having a signal relatedto an in-breath partial pressure of oxygen from exhaled breath of asubject, at least one sensor having a signal related to an in-breathpartial pressure of carbon dioxide from exhaled breath of a subject, anda processor for receiving the signal, the processor further comprisingan algorithm, wherein the algorithm is for substantially identifyingpredicting oxygen saturation in blood based at least in part on thesignals related to the partial pressure of oxygen, and partial pressureof carbon dioxide from exhaled breath of the subject.

Even still another embodiment of the present invention includes abreathing mask sensor system for identifying or predicting dangeroushealth conditions comprising at least three sensors having signals, anda processor for receiving the signals, the processor further comprisingan algorithm, wherein the signal from at least one of the at least threesensors relates to an in-breath partial pressure of oxygen from exhaledbreath of a subject, the signal from at least one of the at least threesensors relates to an in-breath partial pressure of carbon dioxide fromexhaled breath of a subject, and the signal from at least one of the atleast three sensors relates to temperature of exhaled breath of asubject, and wherein the algorithm is for substantially identifying orpredicting oxygen saturation in blood based at least in part on thesignals related to the partial pressure of oxygen, and partial pressureof carbon dioxide from exhaled breath of the subject, and forsubstantially identifying or predicting the subject's core bodytemperature based at least in part on signal related to temperature ofexhaled breath of the subject.

Yet another embodiment of the present invention includes a breathingmask sensor system for identifying or predicting dangerous healthconditions comprising at least one sensor having a signal related to anin-breath partial pressure of oxygen from inhaled breath of a subject,air flow, and rest rate, at least one sensor having a signal related toan in-breath partial pressure of oxygen from exhaled breath of asubject, and a processor for receiving the signals, the processorfurther comprising an algorithm, wherein the algorithm is forsubstantially identifying or predicting oxygen saturation in blood basedat least in part on the signal related to the partial pressure of oxygenfrom exhaled breath of the subject.

Even yet another embodiment of the present invention includes Abreathing mask sensor system for identifying or predicting dangeroushealth conditions comprising at least one sensor adapted to measure anexhaled gas of a subject wearing the mask, the sensor comprising a lightsource, a glass longpass filter, a surface coated in fluorescent dye, aphotodiode, and a conical reflective component adapted to direct lightreflected from the surface coated in fluorescent dye to the photodiode,the sensor also comprising a signal related to a partial pressure ofoxygen of exhaled gas; and a processor adapted to receive the signal,the processor comprising an algorithm adapted to substantially identifyor predict a mass of oxygen absorbed per breath based at least in parton the signal related to the partial pressure of oxygen from the exhaledgas of the subject.

Still even yet another embodiment of the present invention includes abreathing mask sensor system or identifying or predicting dangeroushealth conditions comprising at least one sensor adapted to measure aninhaled gas of a subject wearing the sensor, the sensor comprising alight source, a glass longpass filter, a surface coated in fluorescentdye, a photodiode, and a conical reflective component adapted to directlight reflected from the surface coated in fluorescent dye to thephotodiode, the sensor also comprising a signal related to a partialpressure of oxygen of the inhaled gas; and a processor adapted toreceive the signal, the processor comprising an algorithm adapted tosubstantially identify or predict a mass of oxygen absorbed per breathbased at least in part on the signal related to the partial pressure ofoxygen from the inhaled gas of the subject.

Yet even still another embodiment of the present invention includes amethod of identifying or predicting dangerous health conditionscomprising steps of providing a breathing mask sensor system adapted todetect or predict dangerous breathing or other health conditions, thesensor system comprising, at least one sensor adapted to measure anexhaled gas of a subject wearing the mask, the sensor comprising a lightsource, a glass longpass filter, a surface coated in fluorescent dye, aphotodiode, and a conical reflective component adapted to direct lightreflected from the surface coated in fluorescent dye to the photodiode,the sensor also comprising a signal related to a partial pressure ofoxygen of the exhaled gas; and at least one electronic component,including at least a processor, the at least one electronic componentadapted to receive the signals, the processor further comprising analgorithm; calculating with the processor a mass of oxygen absorbed perbreath based at least in part on the signal from the at least one sensorrelated to the partial pressure of oxygen of exhaled gas; identifying orpredicting with the algorithm dangerous breathing or other healthconditions of the subject based at least in part on the calculated massof oxygen absorbed per breath.

Additional features and advantages of the invention will be set forth inthe detailed description which follows, and in part will be readilyapparent to those skilled in the art from that description or recognizedby practicing the invention as described herein, including the detaileddescription which follows, the claims, as well as the appended drawings.

It is to be understood that both the foregoing general description andthe following detailed description are merely exemplary of theinvention, and are intended to provide an overview or framework forunderstanding the nature and character of the invention as it isclaimed. The accompanying drawings are included to provide a furtherunderstanding of the invention, and are incorporated in and constitute apart of this specification. The drawings illustrate various embodimentsof the invention and together with the description serve to explain theprinciples and operation of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1. Perspective view of one embodiment of the present invention of apilot or aircrew flight mask with multiple sensors used foridentification or prediction of dangerous breathing or other healthconditions.

FIG. 2. Overhead perspective view of an alternative embodiment of thepresent invention of a pilot or aircrew flight mask with multiple,alternative sensors used for identification or prediction of dangerousbreathing or other health conditions.

FIG. 3. Reverse view, cross-sectional depiction of a pilot or aircrewflight mask containing multiple sensors used for identification orprediction of dangerous breathing or other health conditions.

FIG. 4. Schematic depiction of a military pilot in the cockpit of afighter plane, wearing a mask containing sensors used for identificationor prediction of dangerous breathing or other health conditions.

FIG. 5. Schematic depiction of one embodiment of the present inventionof a recirculating diving mask with multiple sensors used foridentification or prediction of dangerous breathing or other healthconditions.

FIG. 6. Schematic representation of a diver wearing a mask with sensorsused for identification or prediction of dangerous breathing or otherhealth conditions, and a flow chart depicting the message, alert, orwarning relay process.

FIG. 7. Flow chart depicting the traditional sensors used and themetrics obtained from those sensors compared to the measured andcalculated metrics obtained from the various embodiments of the presentinvention utilizing gas sensors.

FIG. 8. Flow chart depicting the process of using the present inventionfrom starting air flow, to measurement by one or more sensors, throughtransmission of a warning or other signal for alerting or treatingdangerous breathing or other health conditions.

FIG. 9. Graphs comparing step response of present invention totraditional pulse oximeter in recognizing hypoxia at simulated 25,000feet. FIG. 9A depicts the change in partial pressure of oxygen and 9Bdepicts the change in oxygen saturation.

FIG. 10A. Cross-sectional view of one embodiment of each of the oxygensensor.

FIG. 10B. Cross-sectional view of one embodiment of each of the carbondioxide sensor.

FIG. 11. Perspective view of one embodiment of the data acquisitionand/or processing circuitry (sometimes referred to as a Portable DigitalAnalysis Unit or PDAU) in a singular enclosure with a callout view tothe connection panel of the enclosure.

FIG. 12. Depiction of one embodiment of the data acquisition and/orprocessing circuitry that can be contained in a PDAU.

FIG. 13. Graphical representations of experimental data depicting thechange, over time, based on a simulated steady increase in altitude ofvarious physiological metrics including: 13A) SpO₂; 13B) Hypoxic CardiacResponse; and 13C) Hypoxic Ventilatory Response.

FIG. 14. Graphical representations of experimental data depicting thechange, over time, based on various simulated changes in altitude ofvarious physiological metrics including: 14A) SpO₂; 14B) Hypoxic CardiacResponse; and 14C) Hypoxic Ventilatory Response.

FIG. 15. Graphical depiction of data showing the improved response timeof the present invention with labels with labels indicating the wearer'sphysiological response and the points at which changes are meaningfullydetected.

FIG. 16. Graphical representation of the measurement process and dataflow of the present invention utilizing an oxygen sensor.

FIG. 17. Flow chart depicting various components and subsystems of theprocessing and control circuitry, which may be comprised in a PortableDigital Analysis Unit.

FIG. 18. Model depicting one embodiment of a vehicle-based breathingsystem with oxygen generation and reserve systems with optional oxygenmonitoring sensors on various components.

FIG. 19A. Top view of an optical sensor embodiment employing an opticalcone for directing light from a fluorescing surface toward aphotodetector.

FIG. 19B. Cross-sectional view of an optical sensor embodiment employingan optical cone for directing light from a fluorescing surface toward aphotodetector.

FIG. 20. Schematic representing OBOGS system with novel sensors formonitoring generated gas quality and content.

DETAILED DESCRIPTION OF THE INVENTION

The present invention relates to a monitoring apparatus worn by pilotsand other aircrew during air flight, divers, first responders such asfiremen and rescue personnel, and others who wear breathing maskapparatuses. The system of the present invention is wearable, versatile,small, low-power, minimally invasive, and able to address the monitoringrequirements of numerous conditions, scenarios, and settings. As such,this sensor system, which can be incorporated or attached to a breathingmask is capable of conveniently acquiring physiological metrics andbiometric data of a subject that will mitigate the risks and hazardsassociated with for example high-altitude operations, underwater diving,high-pressure, low-oxygen, and contaminated air environments among itsmany applications. The sensor system is preferably a small, wearablesystem containing at least one sensor for detecting and measuringparticular conditions of the subject's breathing. The system can,however, incorporate other sensors or can be based on sensors other thanthose for directly detecting and measuring particular conditions of thesubject's breath. Further, the sensor system preferably contains atleast one processor comprising algorithms for identifying or predictingdangerous breathing or other health conditions that compute breathingmetrics based at least in part on the signals received from the sensorsof the sensor system. In addition, preferably the sensor system may bedesigned to be retrofitted onto existing breathing mask systems, thusminimizing the amount of hardware and equipment actually necessary toimplement the present invention, while maximizing the utility of thesystem across multiple platforms.

The sensors of the breathing mask sensor system are preferablyintegrated into a breathing mask system and are therefore external tothe subject's body, thus making the present invention a non-invasive orminimally invasive one. The sensors are preferably miniaturized so as tofit into breathing mask systems. In order to measure the breathingconditions and to identify and predict the onset or presence ofdangerous breathing or other health conditions, sensors are requiredwhich have the capability to measure and detect numerous conditionssurrounding the subject. Sensors for detection and measurement of allambient air gases may be used to determine the conditions of bothinhaled and exhaled breaths of the subject. Most importantly, sensorsfor detection and measurement of oxygen and carbon dioxide are usefulfor dangerous breathing condition determinations, but sensors formeasuring many other physiological changes in the subject or formeasuring changes in the subject's environment may be included. Thesesensors include but are not limited to temperature sensors, pulseoximeters, physiological electrodes such as ECG, EOG, EEG, EMG and thelike, accelerometers, gyroscopes, microphones, flow meters, pressuresensors, galvanic skin sensors, respiratory effort belts, oxygensensors, carbon dioxide sensors, organic compound (volatile) sensors andthe like. Such sensors may be optic, pressure transducers, straingauges, dry electrodes, chemical transducers, or of other forms ofsensors known to those skilled in the art.

Many embodiments of the present invention further include sensorslocated throughout the entire environment around the subject. Sensorscan be placed in various subsystems and components of any vehicle orapparatus which the subject is located in or using. In the example ofaircraft, and specifically fighter aircraft, sensors may be located inthe OBOGS systems, any back up or reserve gas supply systems (e.g., EOS,ABOS, and the like), in various other plenum chambers, mounted to thepilot, contained or integrated into the pilot's breathing system, mask,or tubes or hoses, and the like. Any type or variety of sensor can beincluded at these various locations in order to monitor the variousattributes of the gas at each particular point. As described herein,sensors can be used at each of these locations to measure and monitoroxygen, carbon dioxide, flow rates, pressure, temperature, carbonmonoxide, humidity, contaminants and the like. The sensors or sensorsuites may be placed at any of these points in any fashion that allowsthe sensors to measure and monitor the gas at that given point, forexample the sensors may be retrofit and placed onto the individualcomponents, or may integrated into each component as part of thecomponent itself. Individual sensors may be used in various locationswhereby each sensor takes its respective measurements at its dedicatedlocation and transmits the measurements and data to a processor remotefrom the sensor—or local if the sensor happens to be located on or nearthe processors, such as in the PDAU or other processing component.Another alternative is to create what might be referred to as a sensorbank where by numerous sensors are housed together in a given locationand sampling tubes or ports are extended from the sensor bank to thevarious locations of the environment, system or components thereof tohave access to the breathing gas and be able to measure the particularcondition at those locations. As a specific example, a sensor bank maybe created with several oxygen sensors and sensor ports or tubesextending to each of the OBOGS, preferably even each of the separatebeds or media exchange compartments of the OBOGS, ABOS, total outputafter oxygen generation, plenums, any other backup oxygen systems, andpotentially even ambient compartments, thus allowing the system tomeasure the oxygen concentration and/or partial pressure at each ofthose locations using the centralized or banked oxygen sensors. Eachsensor in the bank may be dedicated to a particular location, or, as maybe preferable, the several sensors in the bank can be used to measureconditions from each of the locations at a different time. The benefitto using multiple sensors to measure each of, or a portion of thedesired measurement locations, is that the numerous sensor measurementsprovide a level of redundancy that allows the system to have a built-inerror checking function to ensure that the measurements taken areaccurate. Further, some configurations of sensors in a sensor bank,and/or the use of multiple sensor banks, allow redundancy to be builtinto the system to provide error checking measurements and backupmeasurements systems in the event of sensor failure. The sensors in asingle sensor bank may be linked in a format that allows multiplesensors to measure the same components and/or attributes, or multiplesensor banks may be included in series to provide this redundancy.

The subject's respirations can be measured by measurement of airflow,respiratory effort, oxygenation and ventilation, and the like.Measurement of airflow is preferably measured using sensors or devicessuch as a pneumotachometer, strain gauges, thermal sensors, transducers,piezo sensors, magnetometers, pressure sensors, static charge-sensitivebeds, and the like. These sensors or devices, also preferably measurenasal pressure, respiratory inductance plethysmography, thoracicimpedance, expired carbon dioxide, tracheal sound, snore sound, bloodpressure and the like. Measurement of respiratory effort is preferablymeasured by esophageal pressure, surface diaphragmatic EMG, and thelike. Measurement of oxygenation and ventilation is preferably measuredby pulse oximetry, transcutaneous oxygen and expired oxygen partialpressure monitoring, transcutaneous carbon dioxide monitoring, expiredcarbon dioxide monitoring, and the like. The sensors are preferablyapplied to the subject, his or her equipment or clothing, of the systemin a manner known to those skilled in the art. Preferably, the sensorsare attached or affixed in a non-invasive manner, and preferably to anexternal housing, wearable, or some other deployment method or device.

One example of such a sensor housing, wearable or deployment method ordevice for measuring respirations either directly or indirectly is arespiration belt. Respiration belts can be used to measure a subject'sabdominal and/or thoracic expansion over a measurement time period. Therespiration belts may contain a strain gauge, a pressure transducer orother sensors, which can indirectly measure a subject's respirations andthe variability of respirations by providing a signal, which correlatesto the thoracic/abdominal expansion/contractions of the subject'sabdominal cavity. Respiration belts may be placed at one or severallocations on the subject's torso or in any other manner known to thoseskilled in the art. Preferably, the respiration belts are positionedbelow the axilla and/or at the level of the umbilicus in order tomeasure rib cage and abdominal excursions. More preferably, ifrespiration belts are used then at least two belts are used one beingpositioned at the axilla and the other at the umbilicus.

Another example of such a sensor housing, wearable or deployment methodor device for measuring respirations either directly or indirectly is anasal cannula or a facemask. The sensors integrated with, attached to,or otherwise used in conjunction with a nasal cannula or facemask can beused to measure the subject's respiratory airflow. Nasal or oral airflowcan be measured quantitatively and directly with a pneumotachographconsisting of a standard oxygen nasal cannula or facemask respectivelyconnected to a pressure transducer and placed in the nose or over thesubject's mouth and below the nose respectively. Airflow can beestimated by measuring nasal or oral airway pressure that decreasesduring inspiration and increases during expiration. Inspiration andexpiration produce fluctuations on the pressure transducer's signal thatis proportional to airflow. The oral and nasal components of thesemeasurements can be acquired through the use of at least two pressuretransducers, one transducer for each component. Preferably the twopressure transducers are internal to the interface box and have separateair ports for nasal and oral measurements. Through the use of softwarefiltering, “snore signals” can also be obtained from a sole pressuretransducer signal. The software filtering extracts the high frequencyportion of the transducer signal to obtain the “snore signal.” Therebyeliminating the need for a separate sensor, such as a microphone oranother transducer, and also lessening the system resources needed todetect both snore and airflow. A modified nasal cannula or facemask mayalso be used which is connected to a carbon dioxide or oxygen sensor tomeasure respective concentrations of these gases. In addition, a varietyof other sensors can be connected with either a nasal cannula orfacemask to either directly or indirectly measure a subject'srespirations.

Still another example of such a sensor or method of either directly orindirectly measuring respirations of the subject is the use of a pulseoximeter. Pulse oximeters of any type known to those skilled in the artmay be used. Generally, depending on the location of attachment to thesubject's body, pulse oximeters tend to be either transmission or backscatter (a.k.a., reflection) sensors. Transmission sensors operate bygenerating a source of light at a known frequency and wavelength,passing said light through the subject's body, and measuring the amountof light that exits the subject's body on the other side. Transmissionsensors, and particularly pulse oximeters, are typically applied tofinger tips or the nose, generally due to the thin nature of those partsof the body as well as the ease in applying a sensor to both sides thusenabling the transmission measurement. Other areas of the body do notlend themselves as well to applying such sensors, and thus back scatteror reflection sensors may be used. Back scatter sensors operate bygenerating a source of light at a known frequency and wavelength, andthen measuring the amount of light that bounces or reflects back to themeasurement sensor which is on the same side as the light generator.These sensors are less accurate than transmission sensors due to theloss of light as it scatters once it enters the subject's body—100%reflection is generally unachievable. In spite of the decreasedaccuracy, these sensors, particularly in pulse oximeters, are useful forapplication to the subject's ear to which would be uncomfortable anddifficult to apply a transmission sensor. More specifically, with regardto the preferred sensor, the pulse oximeter can measure the oxygenationof the subject's blood by producing a source of light originating fromthe oximeter at two wavelengths (650 nm and 805 nm). The light is partlyabsorbed by hemoglobin, by amounts which differ depending on whether itis saturated or desaturated with oxygen. By calculating the absorptionat the two wavelengths the proportion of hemoglobin which is oxygenatedcan be estimated. Some embodiments, where the optional pulse oximeter isattached to or incorporated into a helmet, may be referred to ashelmet-mounted pulse oximeter (HMPO_) embodiments. In some embodiments,a pulse oximeter may be placed on a subject's fingertip. In otherembodiments, a pulse oximeter may be placed directly on a subject'searlobe or forehead. In yet other embodiments, a pulse oximeter may beincorporated into a mask, helmet, or some other wearable, and thenplaced on the subject's forehead or earlobe when the mask, helmet orwearable is donned. In still yet other embodiments, a pulse oximeter maybe attached in the subject's ear cup. In yet other embodiments, a pulseoximeter may be incorporated into a mask, helmet, or some otherwearable, and is then placed in the subject's ear cup. In even otherembodiments, a pulse oximeter may be applied to the bridge of thesubject's nose, and is preferably incorporated into a mask, helmet, orother wearable.

Sensor components are preferably miniaturized to accommodate the variousmask types and other systems with which the present invention may beutilized. Sensors of many types and variety may be utilized, butpreferably optical sensors are used—for measuring oxygen and carbondioxide. Optical sensors are those known in the art, which preferablyutilize an emitter, preferably light-emitting diodes (LEDs) which are asemi-conductor light source, and a detector to receive the light fromthe emitter. The detector measures the incoming light and uses thatmeasure to provide a signal which is used to calculate a plethora ofmetrics based on the change in the light as it passes through the gas(in the present invention either the breathing mix, the inhaled breath,or the exhaled breath).

Preferably, the optical sensors used in the present invention utilizedirect coupling between the various components of the sensors,particularly the light source and sensing components. Direct couplingallows the present invention to avoid other forms of coupling presentlyknown in the art which require somewhat remote or relatively distantplacement of light source, sensing and measurement components, such asthrough fiber-optic cable coupling. This remote placement anddistance-coupling can have a negative effect on sensor measurements,particularly requiring extensive and repeated calibration, as well asincreased difficulty and time required for maintenance. The separationbetween the sensor components for such systems greatly increases thenumber and complexity of steps required for such maintenance, and thedecoupling of the components can lead to errors in the calibration thatrequire recalibration to ensure accurate sensor operation. To counteractthese issues, many embodiments of the present invention use directcoupling whereby all sensor components are located together and directlycoupled to each other creating a single, localized unit. Morespecifically, the present invention maintains all sensor componentslocalized to the sensor unit that is part of or attached to the mask, inmost embodiments. This localized system ensures that the sensor remainscalibrated more accurately and with less chance of decalibration,increases the efficiency of the sensor by minimizing the loss of lightin the transmission thereof for sensor operation, and minimizes thesteps and difficulty of cleaning and maintaining the sensor whilethereby further minimizing the risk of calibration errors.

With further respect to calibration of not only the oxygen sensor, butof the sensor suite as a whole, the sensor suite of the presentinvention is preferably capable of calibration such that it monitors theamount of usable life left of the sensor, and further may be capable ofperforming a self-calibration step with respect to atmospheric, ambientor room air. This calibration step is important to ensure accurate andconsistent measurement of each of the individual sensors in the sensorsuite. Typical systems known in the art require the subject and vehicleto be grounded and stationary so that the sensor(s) may be removed andthis room-air-calibration step be performed outside of thesubject-mounted and/or vehicle/mounted breathing system. This process istime intensive and sensitive, and leaves the sensors vulnerable topotential damage while exposed, and further limits the amount of usefultime of the vehicle and subject-mounted systems. The present invention,however, is able to perform a self-calibration, while remaining mountedinto the vehicle- and/or subject-mounted systems. Such capability allowsthe system to maintain its calibration for a longer period of time andrequire system maintenance only when necessary, as opposed to after eachuse like many other systems. Preferably, the calibration of thesensor(s) of the system lasts for at least 100 hours of use. Morepreferably, the calibration of the sensor(s) of the system lasts for atleast 200 hours of use. Yet more preferably, the calibration of thesensor(s) of the system lasts for at least 400 hours of use. Still morepreferably, the calibration of the sensor(s) of the system lasts for atleast 800 hours of use. Even more preferably, the calibration of thesensor(s) of the system lasts for at least 1000 hours of use. Still yetmore preferably, the calibration of the sensor(s) of the system lastsfor at least 1200 hours of use. Yet even more preferably, thecalibration of the sensor(s) of the system lasts for at least 1400 hoursof use. Even yet more preferably, the calibration of the sensor(s) ofthe system lasts for at least 1600 hours of use. Yet still morepreferably, the calibration of the sensor(s) of the system lasts for atleast 1800 hours of use. Even yet more preferably, the calibration ofthe sensor(s) of the system lasts for at least 2000 hours of use.Preferably, the system automatically performs this calibration step uponstartup, and thus calibrates the sensor(s) to the ambient air each timethe vehicle and breathing system or prepared for use by the subject.This eliminates the need to keep the vehicle grounded and stationary,and efficiently allows the system to take accurate, calibratedmeasurements each time the system is in use. For example, in oneembodiment, on startup, the O₂ calibration is adjusted by measuring theambient pressure and assuming that the ambient air is composed of, forexample, 20.9% oxygen expressed as a mole fraction. This partialpressure is used in the calibration curve, computed in reverse, tocalculate the expected raw sensor value at that oxygen level. If thecalibration has drifted due to mechanical shifts, slight thermal shifts,or slight wear or the dye, the calibration curve has been experimentallyunderstood to preserve its shape but otherwise translate linearly. Thefresh-air calibration snaps the calibration curve to the known point.Even though ground-based calibration systems are subject to thedrawbacks discussed above, they are still used for calibration andmaintenance when the vehicles are not in use. Therefore, the addition ofsensors as described herein to ground-based calibration systems canfurther improve the efficiency and reliability of those systems andimprove the quality of the maintenance they provide. The various gas andother sensors (e.g., pressure, flow, temperature, contaminant and thelike) sensors described herein can improve the quality of function ofthe vehicle systems by ensuring that the systems are operating at peakform utilizing the numerous additional measurements not currently usedfor ground-based calibration.

The preferred CO₂ sensor consists of an array of infrared (IR) lightemitting diodes (LEDs) mounted on one side of the sensor, whether thatsensor is designed for measuring the partial pressure of CO₂ in aninhaled or exhaled breath. The carbon dioxide (CO₂) sensor preferablyutilizes an infrared absorption technique that uses several infrared(IR) Light Emitting Diodes (LED) focused on a detector. Preferably, thedetector is a thermo-electrically cooled, and kept at a constanttemperature, detector approximately 1 cm away. Temperature control ofthe sensor (both LEDs and detector) allows for the sensitivity to becontrolled in relative ranges based on the environmental conditions. TheLEDs emit light, preferably at a known input pulse in the range of 4.3μm, exactly the wavelength where carbon dioxide has an extremely strongand unique absorption cross-section. The light passes through the breathor air in the sensor, and strikes a sensor or photodetector whichrecords and measures the output form of the light. Preferably for carbondioxide sensors particularly mounted on a subject's breathing mask, thesensor includes a lens to focus the light as it approaches and strikesthe photodetector to increase the amount of light actually detected bythe detector and thus increase efficiency of the sensor. Where the inputwas preferably a square waveform impulse, the output will be asinusoidal shaped curve as a result of the loss of light attributable tothe light absorbed by the carbon dioxide in the air or breath in thesensor. The amplitude of the output waveform corresponds to thepercentage of carbon dioxide contained in the air or breath. Preferably,a thermo-electric cooler sits behind the IR detector and maintains aconstant temperature at the detector.

Such carbon dioxide sensors can be used in conjunction with flowsensors, as described herein, to calculate the VCO₂, or the volume ofcarbon dioxide produced or output. This combination of sensors and theVCO₂ value can be used to calculate metabolic cost, or the amount ofenergy consumed as the result the subject's particular task.

Further preferably, the present invention is capable of preventingpressure drift in the carbon dioxide sensor measurements which can leadto inaccurate gas concentration measurements. The present inventionpreferably utilizes a bivariate calibration technique that takes intoaccount the barometric pressure at the time of each measurement. Thiscalibration technique thus allows the system to account for changes inpressure based on the use and operation of the system and rapid changesin pressure, for example during intense flight of a military aircraft.This system provides a drastic improvement over typical capnographycalibration methods which typically assume either close-to-groundambient barometric pressure conditions or which acquire a singlebarometric pressure measurement or data point upon startup of thesystem, and then perform all subsequent measurements based on thatbaseline value. The present system, however, continuously takes newbarometric pressure readings during each NDIR reading, and thencalibrates the carbon dioxide sensor based on both the barometricpressure reading and the NDIR reading, in order to obtain the mostaccurate partial pressure of CO₂ measurement possible for accurateprediction, detection and possibly prevention or treatment of dangerousconditions.

The preferred oxygen sensor operates by emitting light at a knownwaveform. Some embodiments may use a square wave, though in otherembodiments the emitted light may be sinusoidally modulated. The oxygensensor operates to emit blue light from an LED diode that excites anorange ruthenium-based dye. The O₂ sensor is preferably used to measurethe partial pressure of oxygen of the subject's breath. The partialpressure of oxygen is preferably measured using the principle ofcollisional fluorescence quenching. A ruthenium-based dye is excited bylight in the visible blue spectrum and emits light in the orangespectrum. Oxygen interferes with the excitation of the ruthenium-baseddye, quenching the intensity of the emission and increasing thefluorescence lifetime. Intensity and fluorescence lifetime are afunction of the collisional rate of oxygen molecules with the dye, whichis a function of partial pressure of oxygen and the temperature. Inorder to isolate partial pressure, which is the quantity of interest,temperature compensation is employed, and the dye fluoresces orangelight that is phase-shifted relative to the excitation light, and thedegree of phase shift is proportional to the oxygen concentration.

More preferably, the sensor is a 465 nm LED (or a 405 nm or 445 nm LaserDiode (LD)) driven by a constant-current driver (in case of laserdiode—this becomes a photocurrent-feedback automatic power controldriver). The light source is driven by a square wave that may be between10 kHz to 40 kHz, preferably operating at a 50% duty cycle. The squarewave is gated at 10 Hz, and preferably operating at a 10% duty cycle,resulting in a total on time of 10 ms per duty cycle. The modulatedlight is preferably turned off during the remaining 90 ms of the dutycycle to reduce photo bleaching, reduce calibration drift, and to savepower. The LED or LD is positioned across from an optical dielectric orcolored glass longpass filter (550 nm) with a high optical density (atleast 4). The LED or LD is separated from the colored glass filter by adistance that allows the divergent beam to fully illuminate the exposedsurface of the filter. The side of the filter proximal to the flowchannel is coated with a thin layer of ruthenium-based dye. As a result,the dye is exposed to the exhaled air and excited by the LED or LD. Insome embodiments, the ruthenium-coated portion of the sensor may be aremovable and replaceable puck or other such modular piece that can beeasily removed and replaced. This extends the life of the sensor overallby allowing the modular puck or component to be replaced as the dye isused up or exhausted. Further, the ruthenium-coated surface or puck maycomprise macro-structures (e.g., ridges, conical protrusions, or thelike) that increase the surface area of the ruthenium available toexcite the emitted light. Increasing the fluorescent surface area leadsto increased fluorescence and more accurate measurements. Preferably,the emitted light that scatters toward the filter passes through thefilter and is detected by a photodiode. In some embodiments, and in allembodiments where the ruthenium-coated surface or puck comprises macrostructures, the sensor further comprises a conical reflective component,or optical cone, surrounding all or a portion of the sensor that iscoated in the ruthenium dye. A trans-impedance amplifier amplifies thephotocurrent from the photodiode. Since the photodiode is unbiased, theamplifier requires careful lag compensation. The amplifier outputvoltage is conditioned by a second-order low-pass filter (45 kHz) andsampled by an analog-to-digital converter at 21 MHz preferably ten timesa second, 10 ms at a time.

The optical cone acts to gather the scattered light after it reflectsfrom the ruthenium-coated surface, and direct it back towards thephotodiode. This conical structure, which may be a frustoconicalstructure, ensures that more of the light is directed back to thephotodiode and thus makes the sensor more accurate. The conicalstructure may also have channels running through it that can serve toallow the gas flow through the channels and across the ruthenium dye aswell as to allow for moisture to escape from the core of the sensor.Either the same channel, or an additional channel in the optical conemay be used as a pressure tap to measure the pressure inside the cone inorder to ensure a more accurate measurement of the partial pressure ofoxygen within the sensor, and can further be used to convert the partialpressure measurement into a fractional amount of oxygen present in thesample. Some embodiments may utilize the internal air pressure gradientof the system to force air through the channels into the sensor, butother embodiments may utilize a pump to actively force air through thechannels. Utilizing the optical cone provides several other benefitsaside from increase light directed to the photodiode. First, the opticalcone structure can allow the entire stack distance of the sensor to bepositively set. The ruthenium dyed surface and the photodiode would thenbe at a constant distance without any flexing or variation in thedistance between the two, and thus provide a more consistent andaccurate measurement by reducing the variables in the operation of thesensor. Second, the entire sensor effectively becomes a single thermalmass capable of more consistent temperature control. Preferably, theoptical cone would be constructed of a thermally conductive material butthe outside of the cone would be constructed of or wrapped in athermally insulative material. This prevents heat exchange between thecone and the external environment while allowing heat exchange betweenthe cone and the environment internal to the sensor. Thus, the cone, theruthenium-coated surface or puck, and the photodiode can all bemaintained much more easily at a steady and uniform temperature. Thetemperature will further be insulated from fluctuations in breathtemperature by the fact that the gas only enters the sensor through theinlet channels or ports, either by pressure differential or active pump.A smaller amount of gas entering the sensor is much more reactive to thetemperature control process, and thus reaches the steady temperature ofthe rest of the thermal mass more quickly. This system additionallyeffectively eliminates the concern of condensation forming on thereflective interior surface of the optical cone which affects theability to reflect light to the photodiode, or on the photodiode whichaffects the ability to receive light. Therefore, the entire sensorbecomes much more stable and accurate in its measurements.

The reflective interior surface of the optical cone allows for increasedmultiples of light to be directed to the photodiode compared to systemswithout such a reflective director. The interior reflective surface ofthe optical cone may fully cover the interior surface of the cone, oronly partially depending on the particular embodiment. Partialreflective coating may be used for many reasons, such as to minimizecost, prevent flow obstruction on the interior of the sensor, easefabrication of the sensor, and the like. Additionally, for embodimentswhere the reflective surface does not over the entire interior of theoptical cone, additional discrete reflectors may be added to thenon-reflective portion, or above the optical cone in the cylindricalpathway at the center of the sensor to direct light to the photodiode.However, regardless of the amount of the interior surface that isreflective, the optical cone serves to increase the amount of lightdirected to the photodiode, thus providing an optical gain. Preferably,the optical cone reflects at least 1.5 times the amount of light to thephotodiode compared to a sensor with no such reflective surfacedirecting light to the photodetector. More preferably, the optical conereflects at least 2 times the amount of light to the photodiode. Yetmore preferably, the optical cone reflects 3 times the amount of lightto the photodiode. Still more preferably, the optical cone reflects atleast 5 times the amount of light to the photodiode. Even morepreferably, the optical cone reflects at least 7 times the amount oflight to the photodiode. Still yet more preferably, the optical conereflects at least 10 times the amount of light to the photodiode. Evenstill more preferably, the optical cone reflects at least 12 times theamount of light to the photodiode. Yet even more preferably, the opticalcone reflects at least 15 times the amount of light to the photodiode.

Another optional feature used to improve optical gain of the oxygensensor is to maximize the surface area of the ruthenium exposed to thegas being measured. One method is to make the ruthenium-coated surfaceor puck a curved surface which will not only increase the surface areabut also can increase the reflection of light from the ruthenium surfaceto the photodiode. For the amount of reflection that is decreased by thealtered surface, the reflective surface of the optical cone will accountfor that and redirect the scattered light to the photodiode. Byimproving the optical gain of the sensor and collecting more light atthe photodiode, the life of the sensor will be able to be increased bydecreasing the intensity of the emitted light which will cause lessfluorescence at the ruthenium surface, thus using the ruthenium lessquickly.

Preferably, the sampled photocurrent waveform is processed on board amicroprocessor or processor with a fast Fourier transform or a Goertzelalgorithm. As the light is emitted at a known frequency and waveform,the photodiode receives the scattered, excited light and outputs asignal in the form of a response waveform. The response waveform of thephotodiode is measured and several metrics are measured or calculatedfrom the response waveform. The magnitude spectrum yields the averageintensity, and the phase spectrum yields the phase shift at 10 kHz, 20kHz, or 40 kHz. The phase shift between the known emitted light and themeasured photodiode response is used to calculate the partial pressureor concentration of oxygen in the measured sample given that the amountof oxygen directly affects the emitted light and shifts the responsewaveform by the measured phase shift. The fluorescence lifetime iscomputed from the tangent of the phase shift at 10 kHz, 20 kHz or 40kHz. The average intensity, fluorescence lifetime, and temperature areplugged into a polynomial computed using the method of least squares.This polynomial is computed by calibrating the sensor's outputs to gaseswith a known and controlled temperature and oxygen partial pressure.This method allows for extremely rapid sensor response times as well astemperature and pressure sensitivity, as well as humidity control byminimizing the effect of these environmental conditions on the sensormeasurements.

The preferred oxygen sensor can operate in either strictly amplitudemode or combining the amplitude and phase-shift. The amplitude methodutilizes an emitted light of a known frequency and waveform (typically asquare wave), and measuring the amplitude of the response waveform. Theamplitude directly correlates with the amount of oxygen contained in thegas sample being measured. The phase-shift technique, in conjunctionwith the amplitude technique, provides the additional metric of thephase angle by which the response wave is shifted, and this combinationof measurements provides the system to measure not only the partialpressure of oxygen but also to determine the life remaining of theruthenium dye. Thus, the sensor, or simply the ruthenium dye puck orcomponent, may be replaced to ensure accurate oxygen concentrationmeasurements. Further still, alternating between amplitude and phaseshift modes my also enhance the bivariate calibration technique wherebypressure is taken into account for each measurement.

Preferably a small thermistor may be thermally coupled to the dye-coatedlong pass filter and interfaced to a measurement circuit. Themeasurement circuit includes a bridge and a timer that samples thethermistor resistance for a short time at a rate of 10 Hz, reducingself-heating effects.

In some embodiments, the oxygen sensor may be a pulse-oximeter modifiedor adapted to be applied someone on the subject's body of one of thevarieties described herein. In other embodiments a pulse-oximeter may beemployed separately from the above described oxygen sensors. Traditionalpulse-oximeters are clipped onto the subject's finger; however, suchconfiguration would be likely to interfere with the subject's dexterityand use of his or her hands, which is entirely undesirable inapplications for which the present invention is designed. Therefore, theoptional pulse-oximeter is preferably designed to be attached to thesubject's body to measure oxygen saturation in some other area, forexample, somewhere on the subject's head, such as in the cup of thesubject's ear. A pulse oximeter may be used in place of the abovedescribed oxygen sensors, or may be used in addition thereto.

The preferred oxygen sensor is further preferably modular in nature,using a beam focusing assembly used to concentrate and focus the beam ofblue light, and with a predetermined optimal distance required betweenthe focusing assembly and the dyed disk. Historically, optical O₂sensors have utilized fiber optic coupling of the blue laser diode andthe ruthenium-coated disc. This has caused such typical O₂ sensors to besomewhat bulky. The present invention, however, preferably miniaturizesthe O₂ sensor by removing the fiber optic coupling and thus removing atypical large component of O₂ sensors, which are the 90° mirror used fordirecting the light, along with the fiber optic cable. Removing thesecomponents allows the sensor to be constructed much smaller, and thus bebetter able to fit into a wearable system. Like the LED for the CO₂sensor, blue laser technology has come a long way since the originalbuild. A blue laser diode is now commonly available thanks to Blu-rayplayers. The result is a much cheaper and smaller technology.

Preferably, all sensors, and in particular the oxygen sensors, arerapid-response sensors capable of sampling the gas flow and determiningthe volume and/or partial pressure of the respective gases very quickly,and are not orientation-sensitive. Preferably, the sensors are capableof taking measurements at a very rapid frequency. More preferably, thesensors are capable of obtaining meaningful samples at a very highfrequency. By meaningful samples, it is meant that the sensors are ableto obtain actual measurements regarding the volume and/or partialpressure of their respective gases, and the time frame is also one inwhich the measured value is capable of making a measurable change.Further, meaningful samples also include the time required for theprocessor or processing device to analyze the sensor signals. Thus, thesystem is preferably able to obtain meaningful samples including sensormeasurement and sensor signal processing, very rapidly. This is asopposed to other sensors, such as pendulum or diffusions sensors, eitherceramic or polymeric as are typically used, which are subject to variousenvironmental factors, and which obtain measurements at a much slowerrate, and as a result require the system to take averaged or estimatedmeasurements from a smoothed curve of values correcting for the slowmeasurement rate and missed or erroneous samples. The rapid-responsesensors of the present invention allow the system to obtain actual, realmeasurements and to monitor substantially real-time changes in gasconcentrations, volumes and/or partial pressures, or any other metricthe sensors may measure. Preferably, the sensors of the presentinvention are able to obtain at least one meaningful sample per second.More preferably, the sensors are able to obtain at least five meaningfulsamples per second. Yet more preferably, the sensors are able to obtainat least ten meaningful samples per second. Still more preferably, thesensors are able to obtain at least fifteen meaningful samples persecond. Even more preferably, the sensors are able to obtain at leasttwenty meaningful samples per second. Still yet more preferably, thesensors are able to obtain at least twenty-five meaningful samples persecond. Yet more preferably, the sensors are able to obtain at leastthirty meaningful samples per second. Even more preferably, the sensorsare able to obtain at least thirty-five meaningful samples per second.Still yet more preferably, the sensors are able to obtain at least fortymeaningful samples per second. Even still more preferably, the sensorsare able to obtain at least forty-five meaningful samples per second.Yet still more preferably, the sensors are able to obtain at least fiftymeaningful samples per second. Still even more preferably, the sensorsare able to obtain at least sixty meaningful samples per second. Evenyet more preferably, the sensors are able to obtain at least seventymeaningful samples per second. Yet even more preferably, the sensors areable to obtain at least eighty meaningful samples per second. Even stillmore preferably, the sensors are able to obtain at least ninetymeaningful samples per second. Most preferably, the sensors are able toobtain at least one hundred meaningful samples per second. With furtherregard to the definition of meaningful samples, each meaningful sample(again including both sensor measurement and sensor signal processingtime) may utilize a large number of individual, and overlapping datapoints as measured by the sensor(s). Preferably, each meaningful samplecomprises at least one sensor measurement data point. More preferably,each meaningful sample comprises at least 100 sensor measurement datapoints. Still more preferably, each meaningful sample comprises at least500 sensor measurement data points. Yet more preferably, each meaningfulsample comprises at least 1000 sensor measurement data points. Even morepreferably, each meaningful sample comprises at least 2000 sensormeasurement data points. Still yet more preferably, each meaningfulsample comprises at least 3000 sensor measurement data points. Even yetmore preferably, each meaningful sample comprises at least 4000 sensormeasurement data points. Yet still more preferably, each meaningfulsample comprises at least 5000 sensor measurement data points. Evenstill more preferably, each meaningful sample comprises at least 6000sensor measurement data points. Yet even still more preferably, eachmeaningful sample comprises at least 7000 sensor measurement datapoints. Even yet still more preferably, each meaningful sample comprisesat least 8000 sensor measurement data points. Still even yet morepreferably, each meaningful sample comprises at least 9000 sensormeasurement data points. Even still yet more preferably, each meaningfulsample comprises at least 10000 sensor measurement data points. Yetstill even more preferably, each meaningful sample comprises at least11000 sensor measurement data points.

Another measure for determining the rate at which the sensors can obtaintheir measurements is actual response time. Preferably, the oxygensensor has a response time of less than 30 seconds. More preferably, theoxygen sensor has a response time of less than 15 seconds. Still morepreferably, the oxygen sensor has a response time of less than 5seconds. Even still more preferably, the oxygen sensor has a responsetime of less than 1 second. Even more preferably, the oxygen sensor hasa response time of less than 500 milliseconds. Still more preferably,the oxygen sensor has a response time of less than 250 milliseconds. Yetmore preferably, the oxygen sensor has a response time of less than 100milliseconds. Still yet more preferably, the oxygen sensor has aresponse time of less than 50 milliseconds. Even yet more preferably,the oxygen sensor has a response time of less than 30 milliseconds.Still yet even more preferably, the oxygen sensor has a response time ofless than 20 milliseconds. Yet still even more preferably, the oxygensensor has a response time of less than 10 milliseconds. Even still yetmore preferably, the oxygen sensor has a response time of less than 50microseconds. Still even yet more preferably, the oxygen sensor has aresponse time of less than 25 microseconds. Most preferably, the oxygensensor has a response time of less than 10 microseconds.

Preferably, the oxygen sensor has a sampling rate of at least 10 Hz.More preferably, the oxygen sensor has a sampling rate of at least 15Hz. Even more preferably, the oxygen sensor has a sampling rate of atleast 20 Hz. Still more preferably, the oxygen sensor has a samplingrate of at least 25 Hz. Even still more preferably, the oxygen sensorhas a sampling rate of at least 30 Hz.

Preferably, the oxygen sensor has an effective measurement range forpartial pressure of oxygen of at least 0.0001 mmHg to 25 mmHg. Morepreferably, the oxygen sensor has an effective measurement range forpartial pressure of oxygen of at least 0.0001 mmHg to 50 mmHg. Even morepreferably, the oxygen sensor has an effective measurement range forpartial pressure of oxygen of at least 0.0001 mmHg to 100 mmHg. Yet morepreferably, the oxygen sensor has an effective measurement range forpartial pressure of oxygen of at least 0.0001 mmHg to 250 mmHg. Even yetmore preferably, the oxygen sensor has an effective measurement rangefor partial pressure of oxygen of at least 0.0001 mmHg to 500 mmHg.Still even more preferably, the oxygen sensor has an effectivemeasurement range for partial pressure of oxygen of at least 0.0001 mmHgto 750 mmHg. Even still more preferably, the oxygen sensor has aneffective measurement range for partial pressure of oxygen of at least0.0001 mmHg to 1000 mmHg.

The preferred temperature sensor for measuring temperature of thebreathing mix, inhaled breath, or exhaled breath is a typical thermistorknown to those skilled in the art. However, an innovative housing anddeployment assembly allows the temperature to be placed directly in theflow of the breathing mix along with a flow meter, alone in the flow ofthe breathing mix, or also in the flow of inhaled or exhaled breath. Thehousing for the temperature sensor is preferably adaptable to attachin-line with the breathing tube for airflow applications. In otherwords, when the temperature sensor is used to measure the temperature ofthe breathing mix as it travels through the breathing tube towards thesubject's breathing mask, the housing connects in-line with thatbreathing tube, thus placing the temperature sensor in the direct flowof the breathing mix. Such a breathing mix temperature sensor may beplaced at the distal end of the breathing tube, or at the proximal end,thus effectively attaching to both the breathing tube and mask, or inseries with the proximal end of the tube and other modular sensors. Thehousing may also be attached to the breathing mask on the exhaled breathside, thus measuring the temperature of the exhaled breath.Alternatively, temperature sensors may be placed in any combination ofthese locations, thus measuring the temperature of the breathing mix,inhaled breath, and/or exhaled breath in any combination. Additionally,temperature sensors of any variety known to those of skill in the artmay be included to measure ambient temperature of the environmentsurrounding the subject. Ambient temperature sensors are particularlyuseful and important for underwater, and more particularly diver,applications where the temperature of the surrounding water may have asignificant and immediate impact on the subject's core body temperature,metabolic rate, and overall health condition.

The temperature sensor housing, while being adaptable to all varietiesof breathing tube and mask systems, preferably employs a system of atleast one airflow separator. More preferably, the temperature sensorhousing employs at list two airflow separator discs with a space inbetween. The thermistor is then attached to the outside of the housing,with the resistor extending into the center of the housing, preferablyon the proximal side of the preferably one air flow separator disc, orbetween the preferably two air flow separator discs. Thus, the housingdeploys the resistor, the temperature measurement portion of thethermistor, into the direct flow of the air or breathing mix to measurethe temperature of that particular gas flow.

Additional temperature sensors as described, or other varieties oftemperature sensors known to those skilled in the art, may be includedto measure various other temperatures related to the subject and thesurrounding environment. Thus, in addition to inhaled and exhaled breathtemperatures, other temperatures may be measured as well. A directmeasurement of the subject's core body temperature may be taken, or maybe calculated based on the inhaled and/or exhaled breath temperatures.Interior ambient temperatures may be measured in cabin, cockpit, orother such vehicle-employed systems, as well as exterior ambienttemperatures, or those outside of the cabin, cockpit, or the like. Fordiving applications, temperature sensors may be included to measureambient water temperature. In other words, temperature sensors may beincluded to measure the temperature of all gases inhaled or exhaled bythe subject, as well as any environmental or ambient temperaturessurrounding the subject, such that the conditions surrounding thesubject may be known and used to help monitor the subject's and system'sstatuses, as well as to detect or predict and mitigate or treatdangerous breathing or other health conditions, and to help alert thesubject or third party.

Many embodiments of the present invention further employ at least onepressure sensor. Pressure sensors may be included inside a breathingmask to measure in-mask pressure. Measuring in-mask pressure allows thesystem to obtain various measurements and metrics that help determinethe subject's condition, such as work of breathing which becomes veryimportant during high pressure (e.g., high g-force or deep water)environments. Preferably, in-mask pressure sensors are puncturelesssensors in that they can be mounted in the mask without the need topunch holes or otherwise permanently modify the mask unit. Thispunctureless sensor allows the mask to be returned to service in otherareas where the in-mask sensor may not be required. One example of anin-mask pressure sensor that can be installed in such a manner is wherethe pressure sensor is coupled with or installed in the same opening asa microphone that is already installed, or able to be installed, intothe mask. Thus, the pressure sensor is able to measure the differentialin-mask pressure without requiring its own port or any modification tothe mask itself. Pressure sensors may also be included in the subject'sgear or clothing, for example a dive suit or a flight vest. Vest or gearor clothing pressure becomes particularly important with regard highaltitude, low pressure environments, such as pilots, aircrew, spacecraftcrew, and the like. Many embodiments of the present invention aredesigned to be used in very low pressure environments, such as thosejust listed. In such environments, pressurized gas is often delivered tothe subject through such a facemask. In order to actually breathe saidgas, the subject often requires clothing or gear (e.g., flight vest) toprovide counterpressure against the lung pressure created by thepressurized gas delivery. Such counterpressure is absolutely necessaryin environments above what is known as the Armstrong Line, which isapproximately located an altitude of 12 miles above sea level (between18,900 to 19,350 meters), and which represents the altitude above whichatmospheric pressure is so low that humans absolutely require apressurized environment to survive. The pressure gradient created by thepressurized environment is what allows the human lungs to perform theirfunction and for breathing to occur. In other words, the requiredpressure gradient, which is the difference between lung pressure andabsolute pressure around the subject, is supplemented or created by theclothing or gear in some embodiments. Thus, pressure sensors in thesubject's gear or clothing in such environments allows the system tomonitor the subject's breathing conditions and detect or predict if thepressure gradient is sufficient to allow healthy breathing. If aninsufficient pressure gradient is detected, the system may then preventor mitigate the onset of dangerous breathing or other health conditionsby adjusting the in-mask pressure, vest pressure, or ambient temperatureaccordingly.

Other pressure sensors may also be included to measure ambient pressuresurrounding the subject. Preferably, pressure sensors used for measuringmask and/or vest or clothing pressure are gauge pressure sensors. Gaugepressure sensors, as known to those skilled in the art, are those inwhich the pressure of the desired space or area is referenced againstambient pressure, and the differential between the two spaces ismeasured. Thus, in the case of a pilot in flight, the sensor formeasuring either mask pressure or vest pressure is preferably a gaugepressure sensor comprising at least two channels for air intake, oneopen to the pilot's mask or flight vest, and the other channel open tothe ambient, in-cabin pressure surrounding the pilot. The differentialbetween the mask or flight vest pressure and the ambient in-cabinpressure is measured to determine the mask or vest pressure. The same orsimilar sensors might be used to measure mask or clothing/gear pressurefor other subjects as well, firefighters, first-responders, rotorcraftpilots and crew, other fixed wing aircraft crew, or any other subjectutilizing such clothing, equipment or gear. Breath-by-breathcalculations require accurate start and end points for each inhalationand exhalation. While inhalation and exhalation traces, as well as gaspartial pressure traces, can be used to estimate these fiducial points,the low flows that occur at the start and end of a breath inherentlyblur these boundaries. Measuring mask pressure allows for the mostaccurate estimation of breath timing. The pressure signal is inherentlyvery low-noise, and the valve cracking pressures are stark signalfeatures that indicate breath start and stop times. The presentinvention preferably utilizes a mask tap device that interfaces amanifold with the communications microphone through vented screws. Thisretrofit allows for a puncture-less mask pressure tap. In addition tobreath timing, the mask pressure signal can indicate valve blockages orinsufficient compensation pressure. For example, the mask pressuresignal can indicate that the user is attempting to exhale but isprevented from doing so due to a blocked valve, or that the user isattempting to inhale, but the supply is providing insufficient pressureto meet the demand, resulting in additional work of breathing that isnot accounted for in other systems.

Work of breathing is the effort required to inspire air into the lungs.Work of breathing becomes more difficult under varying environmentalconditions such as at high altitude, increased depth under water, underhigh g-forces, and other similar environments. It is important to beable to monitor work of breathing because as it becomes more difficult,it is more difficult for the subject to properly inspire and obtainsufficient amounts of oxygen to maintain healthy function. Thus,increased work of breathing can strongly influence the onset ofdangerous breathing conditions as the subject must work harder tobreathe and thus obtains less oxygen through breathing. The sensors andsystem described herein are preferably able to monitor the breathinggases within the system and the conditions under which they are flowingthrough the system in order to monitor the subject's work of breathingwhich can help detect the onset of dangerous breathing conditions. Bymonitoring the level of gas flow as the subject breathes, as well asvarious pressures, the system can determine the work of breathing. Thework is a function of pressure and volume, but the ability of thesubject's lungs to expand and contract in the act of breathing isaffected by the ambient pressure and conditions as noted above. Thus, bycombining the various sensor measurements of the system, the system canfuse the various sensor data to obtain a picture of the environment aswell as the subject's capability to perform the work of breathing inorder to monitor the subject's breathing status. This allows the systemto determine whether the subject is breathing normally, or if the workof breathing is increasing, and thus placing the subject at greater riskof not obtaining the proper mix of breathing gases and exhibitingdangerous breathing conditions.

Still other pressure sensors may also be included. Many embodiments maycomprise at least one pressure sensor for measuring ambient pressureseparately from any user-related pressure. Such ambient pressure sensorsmay be used to separately measure cabin pressure for aircraft andvehicles), ambient air pressure (for man-mounted systems utilized bysubjects on the ground or in non-pressurized vehicle cabins), ambientwater pressure for divers, and the like. Typically, such sensors areabsolute pressure sensors. Absolute pressure sensors are known to thoseskilled in the art to measure the differential between the measuredatmospheric pressure and a sealed atmospheric channel within the sensor.Preferably, the sealed channel, or internal vacuum reference chamber, inthe sensor is substantially set to about 1 atmosphere (atm), which isequal to about 1013.25 millibar (mbar). 1000 mbar is approximately thestandard air pressure at sea level. Thus, the measured ambient pressureis compared against the sealed channel's set pressure, and the measureddifferential between the two is the absolute pressure surrounding thesubject. In many embodiments, gauge pressure sensors and absolutepressure sensors may be used in conjunction with each other to create amore complete pressure profile for the user and his or her environment.Such pressure measurements can then be used, either alone or inconjunction with the measurements and recordings of the other sensorsdescribed herein, to help monitor the subject's status, to help detectand predict the onset of dangerous breathing or other health conditions,to mitigate or prevent the onset of such conditions and their symptomsby triggering a warning or alarm to the user or a third party, ortriggering automated or semi-automated measures such as initiatingbackup oxygen or breathing mix supplies, and the like.

The various pressure sensors described above may have further uses indifferent embodiments of the system as well. For example, a combinationof two differential pressure sensors—one low pressure and one highpressure—can be used in conjunction with the various other sensorsmodules (e.g., oxygen sensor, carbon dioxide sensor, etc.) in order tomaximize the dynamic range of pressure sensing of the given other sensormodule in order obtain gas flow within that sensor module, which in turncan be used to calculate the actual amount of oxygen present in the gassample (breath). Pressure sensors may additionally be used to calibratethe oxygen and carbon dioxide sensors in order to understand whatpressure the sensors are operating at and to detect fundamental issueswith the sensors that can be determined by pressure within the sensormodule. Further, pressure sensor data can be used as input for thevarious levels of calculations of the present invention, including thebi-, tri- or multivariate calculations used to determine the numerousmetrics of the system.

Pressure sensors used with the present invention preferably require lowpower, and are capable of operating accurately and repeatably in extremeconditions (e.g., high pressure, high temperature, low temperature,etc.). The preferred pressure sensors are piezoresistive in nature.Pressure sensors used in the present invention may be of virtually anytype known to those skilled in the art (e.g., Honeywell TruStability®series pressure sensors). If such commercially available sensors areused, they are either altered or repackaged in a housing as describedherein to become modular and readily adaptable for use in the variousbreathing systems and environments for which the present invention isintended to be used. Such housings containing the sensors are then ableto be attached to, combined with, or integrated into breathing systemseither as part of the construction of said system, or as a retrofit ontoan existing system. With regard to the environments in which suchsensors are used, as is known to those skilled in the art, pressuredecreases as altitude increases. Preferably, for ground or airapplications, the pressure sensors used have an effective measurementrange of at least +/−1000 mbar. More preferably, for ground or airapplications, the pressure sensors used have an effective measurementrange of at least +/−900 mbar. Still more preferably, for ground or airapplications, the pressure sensors used have an effective measurementrange of at least +/−800 mbar. Yet more preferably, for ground or airapplications, the pressure sensors used have an effective measurementrange of least +/−700 mbar. Even more preferably, for ground or airapplications, the pressure sensors used have an effective measurementrange of least +/−600 mbar. Still yet more preferably, for ground or airapplications, the pressure sensors used have an effective measurementrange of least +/−500 mbar. Even yet more preferably, for ground or airapplications, the pressure sensors used have an effective measurementrange of least +/−400 mbar. Yet still more preferably, for ground or airapplications, the pressure sensors used have an effective measurementrange of least +/−300 mbar. Even still more preferably, for ground orair applications, the pressure sensors used have an effectivemeasurement range of least +/−200 mbar. Most preferably, for ground orair applications, the pressure sensors used have an effectivemeasurement range of at least +/−100 mbar.

Conversely, for underwater applications, pressure increases as thesubject increases his or her depth, and thus pressure is measureddifferently than for air applications; however, these sensors stilloperate on the same principles. Preferably, for underwater applications,the pressure sensors used have an effective measurement range of least+/−1000 mbar. More preferably, for underwater applications, the pressuresensors used have an effective measurement range of least +/−2000 mbar.Still more preferably, for underwater applications, the pressure sensorsused have an effective measurement range of least +/−4,000 mbar. Yetmore preferably, for underwater applications, the pressure sensors usedhave an effective measurement range of least +/−8,000 mbar. Even morepreferably, for underwater applications, the pressure sensors used havean effective measurement range of least +/−12,000 mbar. Still yet morepreferably, for underwater applications, the pressure sensors used havean effective measurement range of least +/−16,000 mbar. Even yet morepreferably, for underwater applications, the pressure sensors used havean effective measurement range of least +/−20,000 mbar. Yet still morepreferably, for underwater applications, the pressure sensors used havean effective measurement range of least +/−25,000 mbar. Even still morepreferably, for underwater applications, the pressure sensors used havean effective measurement range of least +/−30,000 mbar. Still even morepreferably, for underwater applications, the pressure sensors used havean effective measurement range of least +/−35,000 mbar. Yet even morepreferably, for underwater applications, the pressure sensors used havean effective measurement range of least +/−40,000 mbar. Still even yetmore preferably, for underwater applications, the pressure sensors usedhave an effective measurement range of least +/−45,000 mbar. Even stillyet more preferably, for underwater applications, the pressure sensorsused have an effective measurement range of least +/−50,000 mbar. Yetstill even more preferably, for underwater applications, the pressuresensors used have an effective measurement range of least +/−55,000mbar. Even yet still more preferably, for underwater applications, thepressure sensors used have an effective measurement range of least+/−60,000 mbar. Most preferably, for underwater applications, thepressure sensors used have an effective measurement range of least+/−65,000 mbar.

Many of the sensors included or used with the present invention benefitfrom or require temperature control of the sensor itself in order toperform properly, in particular the preferred oxygen sensor describedherein. Controlling the temperature of the optical sensors allows thesystem to achieve higher efficiency and more accurate and sensitivemeasurements while simultaneously preventing environmental problems thatarise during use, for example condensation on the optical surfaces andthermal drift of the sensor readings. Issues such as these arise inapplications where a particularly high concentration of a gas is presentand in environments where extreme temperatures exist, and lead toinaccurate and potentially dangerous sensor measurements. As an exampleof the effect such conditions have on optical sensors, ruthenium-basedoxygen sensors, such as described herein, tend to exhibit diminishedsensitivity at high concentrations of oxygen or at high temperatures.Therefore, in environments such as those the present invention isconcerned with, where a gas source or generator (e.g., oxygen tank,OBOGS, or the like) provides a high concentration of oxygen, and thusdecreases the sensitivity of the sensor. However, by heating or chillingor cooling a ruthenium-based (or other similar fluorophore-based)sensor, the measurement sensitivity curve of the sensor shifts andallows the sensor to more accurately measure the higher concentrationsof oxygen. Temperature control methods (heating vs. cooling) depend onthe particular fluorophore and/or the placement of the sensor, but thegoal is to maintain the sensor and potentially the gas being measured ata constant temperature. Conversely, if the sensor is warmed or heated,then the measurement sensitivity curves shifts in the oppositedirection. Thus, warming such a sensor would allow for more accuratemeasurements at exceedingly low oxygen concentrations. Although theindividual sensor temperature control is described in terms of aruthenium-based oxygen sensor, the same concept may be applicable tooxygen sensors using other similar fluorophores as well, or for othersensors such as carbon dioxide sensors. The goal of the temperaturecontrol system is to balance the temperature with the concentration ofthe gas being measured in order to maintain the highest sensitivity ofthe sensor possible so that the sensors are able to measure smallerchanges in the gas concentration and provide more robust measurementsand predictions of dangerous breathing or other health conditions.

As noted above, gas concentration is not the only factor that affectsthe sensor measurements or readings that may be dealt with bycontrolling the temperature of the sensors. Often, condensation canbuild up on the optical surfaces and cause errors, artifacts, or othergenerally inaccurate measurements. However, controlling the temperatureof the optical sensors, and particularly the optical surfaces thereof,allows the system to reduce, eliminate and even prevent condensationfrom building up on those surfaces, and thus maintain the most efficientand accurate measurements possible. This system allows the presentinvention to operate in very humid (thus highly likely to allowatmospheric moisture to condense on the optical surfaces) environments,where no other existing system can presently operate with the sameaccuracy. Thus, by controlling the temperature of the optical sensors,preferably the optical sensors are capable of operating and accuratelymeasuring in environments of 25% humidity or greater. More preferably,the optical sensors are capable of operating and accurately measuring inenvironments of 50% humidity or greater. Still more preferably, theoptical sensors are capable of operating and accurately measuring inenvironments of 60% humidity or greater. Yet more preferably, theoptical sensors are capable of operating and accurately measuring inenvironments of 75% humidity or greater. Even more preferably, theoptical sensors are capable of operating and accurately measuring inenvironments of 85% humidity or greater. Still yet more preferably, theoptical sensors are capable of operating and accurately measuring inenvironments of 90% humidity or greater. Yet still more preferably, theoptical sensors are capable of operating and accurately measuring inenvironments of 92% humidity or greater. Even still more preferably, theoptical sensors are capable of operating and accurately measuring inenvironments of 94% humidity or greater. Still even more preferably, theoptical sensors are capable of operating and accurately measuring inenvironments of 96% humidity or greater. Yet even more preferably, theoptical sensors are capable of operating and accurately measuring inenvironments of 98% humidity or greater. Most preferably, the opticalsensors are capable of operating and accurately measuring inenvironments of 100% humidity.

In order to provide such temperature control for sensors, suchembodiments preferably include a temperature controller for adjustingand maintaining the temperature of the various optical sensors. Variousembodiments may utilize a single temperature controller, or there may bemultiple, individual controllers for the various components of thesystem. Preferably, multiple temperature controllers are used to givemore accurate and specific control of the temperature of the variouscomponents. The temperature controllers may take any form that is ableto change the temperature of the various components with a high degreeof accuracy and consistency to avoid temperature drifting, for example ahighly efficient thermoelectric cooler or heater. By way of non-limitingexample, one embodiment of the present invention may include three suchtemperature controllers in a breathing-mask system. In this example, themask comprises an inhaled-side oxygen sensor, and both a second oxygensensor and a carbon dioxide sensor on the exhaled-side, as well as threetemperature controllers. One temperature controller is used to controlthe temperature of the Ruthenium dye of the inhaled-side oxygen sensor.Controlling the temperature of the dye allows the system to shift thesensitivity of the sensor based on the concentration of oxygen presentin order to maintain the balance between oxygen and temperature andensure that the sensor is operating at a highly sensitive level. On theexhaled-side oxygen sensor, one temperature controller may be used tocontrol the temperature of not only the Ruthenium dye of the sensor,which is performed in much the same manner as the inhaled-side oxygensensor, but also the photodiode when such control is desired. Thephotodiode of the exhaled-side oxygen sensor is preferably temperaturecontrolled because it can tend to exhibit shifting wavelengths of lightbased on the temperature, which can lean to inconsistent or inaccuratemeasurement of the various signals (described in greater detail below)that are measured on the exhaled-side but not the inhaled side. Thewavelength shift on the inhaled side can be accounted for with a basictemperature measurement and calibration without requiring control of thetemperature of the diode. For the exhaled-side oxygen sensor, the actualtemperature of the photodiode is relatively irrelevant, so long as itremains constant. Therefore, this exemplary embodiment uses a singletemperature controller for both the dye and the diode of theexhaled-side oxygen sensor so that both are maintained at the sametemperature that allows the sensor to be as sensitive as possible whilemerely maintaining a steady temperature for the diode to ensure aconstant emission wavelength. Thus, the entire sensor can be maintainedat the highest sensitivity and accuracy as possible. Lastly for thisexemplary embodiment, a third temperature controller is used to controlthe temperature of the photodiode for the exhaled-side carbon dioxidesensor, also in order to maintain a constant emission wavelength forconsistency, accuracy and sensitivity of the sensor.

As noted above, the exhaled-side sensors of various embodiments of thepresent invention may perform a more complex set of functions beyondmerely taking a measurement of the respective gas concentration.Effectively, these sensors may obtain a series of three or more separatesignals or measurements in order to provide a single gas concentrationmeasurement value that is accurate and accounts for the variousenvironmental and controlling effects (e.g., temperature control asdescribed above) being placed on the exhaled-side sensors. A gasconcentration measurement is taken, and is then effectively calibratedor adjusted based on the adjustments to the sensors by a set of twoother signals or measurements that can be referred to as a backgroundsignal and a reference signal. By way of non-limiting example, using theexhaled-side oxygen sensor of one embodiment of the present invention, abasic oxygen measurement with the oxygen sensor is obtained using a bluediode to excite the ruthenium dye, then a second measurement is obtainedwith no light being shined, and then a third measurement is obtainedwhere a red light of known wavelength that may be situated near theruthenium dye is shone back through the gas flow. The blue lightmeasurement is just as described above with regard to normal oxygensensor function and provides an oxygen measurement (O₂ Sig) of the gasbeing exhaled. The second measurement with no light emission is thebackground signal (Bkg) which represents the background or ambient lightpresent in the sensor, and the third measurement with the red light isthe reference signal (Ref) which represents a specifically known valuethat is not affected by the gas in the gas flow chamber. Thus, withthese three measurements, the system can provide an oxygen concentrationvalue that is calibrated for background light and condensation bycalculating the ratio shown in equation 4:

$\begin{matrix}\frac{{O_{2}{Sig}} - {Bkg}}{{Ref} - {Bkg}} & \left. 4 \right)\end{matrix}$Thus, in this example, the calibrated oxygen concentration value is moreaccurate and takes into account the environmental factors (e.g., ambientlight) and controlling factors (e.g., wavelength of excitation light anddye from temperature control) to provide a more accurate and precisemeasure.

The optical sensor components are preferably placed in mechanicalattachment housings for each of the different sensors, or combinationsthereof. These sensor housings are used to secure the oxygen, carbondioxide, and other sensors to the facemask or in-line with the breathingtube, and are preferably optimized for size and weight and are machinedand fabricated of performance materials capable of withstandingconditions of extremely high pressure, extremely low pressure, torque,g-forces, high and low temperature, and the like. The sensors are allpreferably man-mounted, that is, in some way attached or affixed to theuser or his or her gear or clothing, as opposed to being vehicle- orotherwise externally-mounted. Further preferably, the sensors are eachg-force-insensitive in that they are not affected, nor is theirfunction, by high g-force environments. Many embodiments of the presentinvention utilize a strain relief system whereby any mechanicalconnections between sensors and the system or interior to the sensorsthemselves are reinforced so that under high g-forces the mechanicalconnections will not pull apart and separate. Another way to ensureaccuracy is to use solid state sensors with no moving parts that wouldbe affected by such environments. The housings are preferably flexiblethough rigid. Such materials may include, but are not limited toplastics (list types of plastics), rubber (types of rubber), or thelike. The sensor housings are preferably designed to be modular andadaptable to be retrofitted onto virtually all existing and laterdeveloped breathing masks and breathing tube systems. The housings andsensors may also be deployed in a self-contained system without beingadapted to or attached to an existing system. In many embodiments, thevarious sensors of the present invention may be combined, packaged orenclosed in such attachment housings together to minimize the number ofhousings, modules, and/or attachments that might be required to performthe necessary measurements. By way of non-limiting example, in onepreferred embodiment, an oxygen sensor and a carbon dioxide sensor arehoused together in a single enclosure or attachment housing, thiscreating a single sensor unit, which is then attached to the exhalationside of the mask. Thus, the single exhaled-side sensor unit comprisesboth the oxygen and carbon dioxide sensors which measure theirrespective gas concentrations as the user exhales without requiringmultiple enclosures which would be more bulky and cumbersome. A personhaving ordinary skill in the art will understand which sensors mayrealistically and conveniently be housed together while neither impedingthe function of the individual sensors or the system as a whole.Further, the sensors and sensor housing are all preferably miniaturizedin order to decrease the weight of the system as a whole and to make iteasier for the subject to wear for longer periods of time with minimaldiscomfort and draining of energy.

Another embodiment utilizing externally mounted sensors or sensor suitesmay include a smart mask which provides a real-time monitoringcapability to monitor the subject's breathing on a breath-by-breathbasis, where the mask is attached to gas supply—either a gas generationsystem such as an OBOGS, a finite gas supply such as a tank or otherreserve that is attached, mounted or worn by the subject. The sensorsuite of the smart mask embodiments preferably monitors and measures thesubject's breathing as breath occurs, and determines an on-demand needfor breathing gas, for example oxygen. Thus, as the subject exhibits aneed for supplemental breathing gas, the sensor(s) or sensors suite ofthe smart mask make such determination based on their measurements andgas is supplied as needed. Again, such a smart mask may include sensorsas described herein, including, but not limited to oxygen, flow rate,carbon dioxide, pressure, temperature, and other sensors. Such smartmasks may be used in any type of vehicle within the scope of the presentinvention, but may also be used for subject-mounted breathing tanksystems where the gas supply is born by the subject. On-demand breathinggas supply allows for a smaller reserve or tank of breathing gas to becarried while increasing the length of its utility.

Another embodiment of the present invention does not require external orseparate sensor housings by which the sensors are attached or mounted toa breathing mask, but instead include a fully integrated mask withsensors incorporated into the mask itself, rather than attached to themask. Such integrated mask embodiments may include a separate sensorchamber located within the mask that is separate from the breathingpathway of the mask. This sensor chamber may receive breathing gas via asmall orifice, channel or inlet port that is located near the subject'smouth. The gas may enter the sensor chamber via differential pressuredrawing and pulling the gas into the chamber, or a small pump may beused to actively force gas into the chamber. Another benefit of samplingvia a small orifice, channel or inlet port is that of reducing moisturein the sensors and sensing mechanism. Breath naturally contains variousforms of moisture that can clog or interfere with the gases entering thechamber, the minimization of gas flow turbulence related to the cadenceof the subject's breathing, and the increase of data output quality byeliminating the need for a hose connecting the subject's mouth and thesensors in the sensor chamber for transmitting gas to the sensors. Flowsensors placed on either or both sides of the mask can provide flow datathat can be overlaid with the data from the other sensors, such asoxygen, carbon dioxide, and other sensors described herein. Preferably,at least one each of oxygen sensors, carbon monoxide sensors, carbondioxide sensors, flow sensors, pressure sensors, temperature sensors,contaminant sensors, humidity sensors, or a combination thereof, areincluded in the integrated mask system. Preferably, the sensorcombination of the integrated sensor and mask embodiments providessimilar information to that of a metabolic cart. Gases can be sidestreamed to the sensors or sensor module and measured for theirappropriate attributes depending on the included sensors, and the systemcan output data essentially the same as would be provided by a metaboliccart in appropriate environments, thus providing a known or comfortabletype of data to be analyzed by clinicians.

Integrated mask embodiments may further include other sensors within themask as well. Some embodiments may include at least one accelerometerand one gyroscope in the sensor chamber. The accelerometer and/orgyroscope allow the system to track the subject's head position whichcan be used to determine and monitor the subject's level ofconsciousness. Head orientation may also be used to specificallydetermine if the subject is becoming drowsy or awareness is fading, orto help ensure proper posture for certain maneuvers, such as thoseengaged at high g-strain. Some embodiments may include a full suite ofmotion sensors capable of monitoring up to nine axes of movement, suchas by including 3 axes of accelerometer data, 3 axes of gyroscope dataand 3 axes of magnetometer data. The integrated mask system may alsoemploy an advanced check valve system to help keep the inhaled andexhaled-side gases separate, and which may utilize a hysteresis controlloop that can help reduce the subject's work of breathing and thus makebreathing easier for the subject, which can help reduce, mitigate orprevent the onset of dangerous breathing conditions. In some preferredembodiments, the sensor chamber can be used to evaluate both the inhaledbreath and exhaled breath gases individually and separately, due largelyin part to the check valve implemented therein. BY performing suchbreath evaluation inside the integrated mask, this eliminates the needfor externally mounted sensors as described in other embodiments herein,particularly the exhaled breath sensors mounted directly to the mask andin concert with the check valve, and the inhaled breath sensors oneither the proximal or distal end of the breathing tube.

The various sensors or combinations of sensors that may be used in thesensor chamber of the integrated mask embodiments can further be used tohelp with the reduction, mitigation or prevention of the onset ofdangerous breathing conditions. The sensors, based on their readingsand/or measurements, can be used to activate various systems formitigation or prevention. For example, the sensor measurements mayindicate that the subject is becoming hypoxic and thus either trigger awarning to notify the subject to initiate a backup oxygen supply, or mayinitiate the supplemental oxygen automatically based on the level of thesubject's hypoxia. Thus, the sensors could either trigger a notificationto the subject to find a mitigating solution, or to activate (ordeactivate) systems such as the ABOS or EOS. Further, the sensors may beused to trigger notifications that normal breathing has resumed and thesubject can shut off the mitigating solutions (if possible), orautomatically cease operation of the mitigating solutions. Even beforemitigating or preventative measures are necessary, the sensor chambermodule can be used to monitor and/or control the breathing airgenerating systems of the vehicle for a variety of vehicles including,but not limited to, warfighters and military aircraft and vehicles,commercial aircraft and vehicles, general aviation cabin environments(such as to determine when the pilot needs to don an oxygen mask), andthe like.

The sensor chamber may be a fully integrated system that is built in tothe structure of the mask. More preferably, the sensor chamber may be amodule that can be installed and/or removed from individual masks withrelative ease. The sensor chamber module may be mask specific, but morepreferably may be interchangeable with other masks of the same variety,or even with different mask types. The sensor modules may be adapted tobe usable with various types of pilot masks (warfighter, high altitude,commercial, etc.), diving masks, recirculating breathing systems,astronaut suits, first responder masks, ski masks, self-containedbreathing apparatuses, parachutist masks, high altitude ground troopsmasks, hikers, and the like. The sensor chamber module may further beable to interface with many types of breathing mask systems, such asbreathing tubes of aircraft with OBOGS as described herein, butpreferably some embodiments may be able to interface with breathingsystems using nasal cannulas, or those using breathing bags, forexample. Specially adapted sensor chamber modules may be able toevaluate the effectiveness of breathing bag systems and to monitor andassess the subject's pulmonary function as the bag is used to force airinto the subject's lungs.

The sensor chamber modules may be still further adapted for use in othersystems as well, not just in relation with vehicle-based breathingsystems. The sensor chamber modules may be utilized in medical caresettings or other similar arenas where the sensor chamber module may beintegrated into respiratory monitoring systems and used to evaluate theeffectiveness of drugs or medications as well as to assess the dosinglevels and overall reaction of the subject. One example would be tomonitor and assess the dosing of gases through an inhaler or through agas delivery system in a hospital or medical transport. The sensorchamber system can be used to monitor the subject's pulmonary functionas a result of the drug or medication provided and provide outputincluding any attendant warnings or alarms.

The flow sensor is preferably a micro-electromechanical systems (MEMS)differential pressure Delta P head loss sensor, though can be any typeof flow sensor known in the art, including but not limited to hot filmanemometer or mechanical impeller-type. The flow sensor may be of a typereadily available and known to those in the art, for example, acommercial off-the-shelf flow sensor from Honeywell (e.g., HoneywellAWM700 series Airflow sensors). Such a commercial flow sensor isrepackaged into an innovative housing to fit into the breathing maskhose, in a manner similar to the temperature sensor housing describedabove. The flow sensor may also be of other varieties known to those inthe art, such as turbine sensors, other MEMS-based sensors, ultrasonicsensors, and the like. As such, the flow sensor is preferably placed atthe distal end of the breathing tube. For example, in a typical flightsystem, such as a combat pilot breathing mask, the flow sensor would besituated between the distal end of the breathing tube and the typicalCRU94 or other inhaled regulator fitting which provides pressurebreathing to the aircrew wearing the mask. Alternatively, the flowsensor may be adapted to fit inside the breathing tube. Still anotheralternative is to integrate an entire inhalation sensor module with theCRU in order to minimize discrete systems within the overall system.Such an inhalation sensor module may include more than just flowsensors, such as also providing oxygen sensor(s), temperature sensors,pressure sensors, particulate and contaminate sensors, and the like.Preferably, at least an oxygen sensor and a flow sensor are used.Optionally, the repackaged housing contains flow dividers that create asmall pressure drop across the sensor, separating the flow into twoseparate channels: one a bypass channel with no sensor, and the otherbeing a measurement channel whereby the gas flows over the flow sensor.By way of non-limiting example, in one embodiment utilizing a flowsensor (such as the Honeywell model # AWM720P1 flow sensor) rated for aneffective measurement range of 0-200 ALPM (actual liters per minute) orSLPM (standard liters per minute), and where the gas flow rate is about400 liters per minute (LPM), the sensor would be unable to effectivelyrecord measurements at such a high flow rate. However, the flow sensordivider separates the flow such that approximately 200 LPM flows througheach of the bypass channel and the measurement channel, wherebymeasurements are taken at 200 LPM and the data is then extrapolated backto a 400 LPM flow rate. The sensor outputs an analog voltage ofpreferably 0-5V which is a nonlinear function of the mass flow rate ofair, calibrated in standard liters per minute. Preferably, the samplingrate of the flow sensor is greater than about 10 Hz. More preferably,the sampling rate of the flow sensor is greater than about 25 Hz. Stillmore preferably, the sampling rate of the flow sensor is greater thanabout 35 Hz. Yet more preferably, the sampling rate of the flow sensoris greater than about 50 Hz. Even more preferably, the sampling rate ofthe flow sensor is greater than about 65 Hz. Still yet more preferably,the sampling rate of the flow sensor is greater than about 75 Hz. Evenyet more preferably, the sampling rate of the flow sensor is greaterthan about 90 Hz. Yet still more preferably, the sampling rate of theflow sensor is greater than about 100 Hz. Even still more preferably,the sampling rate of the flow sensor is greater than about 115 Hz. Yeteven more preferably, the sampling rate of the flow sensor is greaterthan about 125 Hz. Still even more preferably, the sampling rate of theflow sensor is greater than about 140 Hz. Yet even still morepreferably, the sampling rate of the flow sensor is greater than about150 Hz. Most preferably, the sampling rate of the flow sensor is greaterthan about 175 Hz. The true effective upper frequency range of the flowsensor is, in practice, limited by the frequencies of the other sensorsemployed in a particular embodiment. Also, with regard to the effectivemeasurement range, preferably the flow sensor has an operating range of0-50 SLPM or ALPM. More preferably, the flow sensor has an operatingrange of 0-100 SLPM or ALPM. Yet more preferably, the flow sensor has anoperating range of 0-200 SLPM or ALPM. Even more preferably, the flowsensor has an operating range of 0-300 SLPM or ALPM. Still morepreferably, the flow sensor has an operating range of 0-400 SLPM orALPM. Even yet more preferably, the flow sensor has an operating rangeof 0-500 SLPM or ALPM. Yet still more preferably, the flow sensor has anoperating range of 0-600 SLPM or ALPM. Still even more preferably, theflow sensor has an operating range of 0-700 SLPM or ALPM. Even stillmore preferably, the flow sensor has an operating range of 0-800 SLPM orALPM. Yet even more preferably, the flow sensor has an operating rangeof 0-900 SLPM or ALPM. Still yet more preferably, the flow sensor has anoperating range of 0-1000 SLPM or ALPM.

Flow sensors can be used to assess the subject's level of fatigue atvarious stages of a mission or use, to calculate work of breathing,tidal volumes of breath and other such physiological metrics. Further,these metrics can be used as a training tool to help provide aquantifiable value pertaining to how well the subject, such as a pilot,is performing certain activities, such as g-strain maneuvers in flightor training. The flow sensors can also be used to detect physiologicalprecursors associated with G-LOC, particularly in combination withpressure and gas sensors, in order to help predict the onset ofdangerous breathing conditions and direct the subject to either preventor mitigate the dangerous conditions.

Different types of sensors for measuring physiological signals from thesubject can be used preferably when these sensors can be incorporatedinto a facemask. These sensors include electrodes for measuringelectro-physiological signals such as EEG, ECG, EMG, ENG, ERG, EOG andthe like. These electro-physiological signals can be obtained by anymethod known in the art, and are envisioned to cover those sensorssubsequently developed by those skilled in the art to detect these typesof signals.

For example, the sensors can be magnetic sensors. Sinceelectro-physiological signals are, in general, electrical currents whichproduce associated magnetic fields, the present invention furtheranticipates methods of sensing those magnetic fields to acquire brainwave signals similar to those which can be obtained through, forexample, an electrode applied to the subject's scalp. The subject(s)referred to in the present invention can be any form of animal.Preferably the subject(s) are mammal, and most preferably human.

If electrodes are used to pick up the electro-physiological signals,these electrodes for example when measuring brain wave or EEG signalsmay be placed at one or several locations on the subject(s)' scalp orbody—preferably on the forehead or around the face so they can beincorporated into the facemask. The electrode(s) can be placed atvarious locations on the subject(s) scalp and preferably the forehead inorder to detect EEG or brain wave signals. In order to obtain a good EEGor brain wave signal it is desirable to have low impedances for theelectrodes. Typical EEG electrodes connections may have impedance in therange of from 5 to 10 K ohms. It is in generally desirable to reducesuch impedance levels to below 2 K ohms. Therefore, a conductive pasteor gel may be applied to the electrode to create a connection withimpedance below 2 K ohms. Alternatively or in conjunction with theconductive gel, the subject(s)'skin may be mechanically abraded, theelectrode may be amplified or a dry electrode may be used. Dryphysiological recording electrodes of the type described in U.S. Pat.No. 7,032,301 are herein incorporated by reference. Dry electrodesprovide the advantage that there is no gel to dry out, no skin to abradeor clean, and that the electrode can be applied in hairy areas such asthe scalp. Additionally if electrodes are used as the sensor(s),preferably at least two electrodes are used—one signal electrode and onereference electrode; and if further EEG or brain wave signal channelsare desired, the number of electrodes required will depend on whetherseparate reference electrodes or a single reference electrode is used.For the various embodiments of the present invention, preferably anelectrode is used and the placement of at least one of the electrodes isat or near the occipital lobe of the subject's scalp. Preferably, invarious embodiments these dry electrode sensors are connected to orembedded in the facemask. Dry physiological electrodes can be integratedinto various parts of the system to further monitor ECG signals and/orEOG signals in order to better assess the physiological and cognitivecondition of the subject.

If electrodes are used to pick up the electro-physiological signals,these electrodes, for example when measuring cardiac signals using anECG, may be placed at specific points on the subject's body. The ECG isused to measure the rate and regularity of heartbeats as well as thesize and position of the chambers, any damage to the heart and indiagnosing sleeping disorders. As the heart undergoes depolarization andrepolarization, electrical currents spread throughout the body becausethe body acts as a volume conductor. An ECG is important as a tool todetect the cardiac abnormalities that can be associated withrespiratory-related disorders. The electrical currents generated by theheart are commonly measured by an array of preferably not more than 10electrodes, placed on the body surface. Preferably electrodes are placedon each arm and leg, and six electrodes are placed at defined locationson the chest. The specific location of each electrode on a subject'sbody is well known to those skilled in the art and varies amongstindividual and different types of subjects. Although a full ECG testusually involves ten electrodes, only two are required for many testssuch as a sleep study. These may be placed on the subject's left-handribcage, under the armpit and on the right-hand shoulder, near theclavicle bone, or in other convenient locations on either side of thesubject's body. These electrode leads are connected to a devicecontained in the signal-processing module of the present invention thatmeasures potential differences between selected electrodes to produceelectrocardiographic tracings.

There are two basic types of ECG leads: bipolar and unipolar. Bipolarleads (standard limb leads) utilize a single positive and a singlenegative electrode between which electrical potentials are measured.Unipolar leads (augmented leads and chest leads) have a single positiverecording electrode and utilize a combination of the other electrodes toserve as a composite negative electrode.

Other sensors can be used to measure various parameters of a subject'sphysiological condition. These other parameters are preferably measuredusing sensors or devices such as a photodetectors, accelerometers,pneumotachometers, strain gauges, thermal sensors, transducers, piezosensors, magnetometers, pressure sensors, static charge-sensitive beds,audio monitors, video monitors and the like. Since the system isprogrammable potentially any transducer type sensor, that is any sensorthat outputs an electrical signal, can be used with the system.

Accelerometers may be used to measure determine the subject's bodyposition and orientation, g-forces, and provide other functions such asproviding time synchronization with the subject's vehicle (e.g.,aircraft). Such accelerometers may be of any type known to those skilledin the art, including magnitude accelerometers and 3-axisaccelerometers. Accelerometers are often included to detect high g-forceconditions, and thus to help monitor, predict, mitigate and alert theuser or a third party as to the onset or occurrence of dangerousbreathing or other health conditions as a result of such high g-forcecondition or maneuver. The time synchronization feature primarily allowsfor post-mission or post-application review of data in which thesubject's position and orientation, as well as g-forces experienced arecompared via time signature to known events or occurrences, such asdetected dangerous breathing or other health conditions. This helps toalign data points in order to allow and facilitate analysis of whatcircumstances may lead to or cause the onset of dangerous breathing orother health conditions in order to help develop new preventative,mitigating, or treatment systems and methods.

The sensor system of the invention preferably is in communication with alocal processor or other electrical components for receiving signalsfrom the sensors and for calculating a number of measures and metricsbased at least in part on the signals from the sensors. The processormay be in direct, wired communication with the sensor or sensors.However, communication between the sensors and the processor may bethrough wireless means. Preferably, the processor is also sufficientlyminiaturized to be optimally placed in a contained pocket, sleeve, orthe like located on the subject's clothing or in a self-contained systemor module. Alternatively, the processing components may be sufficientlyminiaturized to fit and/or be integrated into the CRU along withsensors. Such embodiments have the benefit of drawing power from thevehicle and not requiring an integrated power supply in the PDAU, andcan integrate the data stream directly into the onboard aircraftprocessing architecture. The processor preferably contains and employsan algorithm for the specific purpose of identifying and predictingdangerous health conditions including, but not limited to hypoxia,hypothermia, hypo- and hyperventilation, G-LOC, atelectasis and otherdangerous breathing and physical conditions. Preferably, the algorithmin many embodiments identifies or predicts a mass of oxygen absorbed bythe subject based at least in part on the signal or signals from thevarious sensors which may be included with the system. Furtherpreferably, the algorithm then uses the identified or predicted mass ofoxygen absorbed to identify or predict the onset of a dangerous healthcondition in the subject. The processor preferably includes anelectronics board and housing, and the processor as a whole ispreferably not larger than the volume of a typical flight suit pocket.The processor is further preferably able to relay a signal or warning tothe subject, a third party, such as a dive master, team member, or thelike, when dangerous conditions, and more preferably dangerous breathingor other health conditions are detected or predicted. Also, in someembodiments involving a closed-loop breathing system, the processor isable to calculate an optimal breathing mix of gases, and to recalibratethe system to provide that breathing mix and thus correct or avoidpotentially hazardous breathing conditions, for example by automaticallyincreasing the amount of oxygen provided by the system. Such systems mayutilize the in-place OBOGS system and simply increase its output, or mayutilize secondary oxygen supply reserve systems, such as bottled gaseousoxygen or liquid oxygen, both of which preferably include ahumidification system to avoid drying out of the subject's breathingpassageways. The processor, in many other embodiments, further controlsoxygen or breathing mix dosing, which is a method of control gasdelivery based on perceived, measured, or calculated need and whichhelps to extend the life of gas supplies. Oxygen or breathing mix dosingis particularly useful for systems comprising reserve or backup gassupplies such that in the event of main or primary gas supply failure,the reserve or backup supply is preserved and extended for as long aspossible to maximize the likelihood that the subject is able to returnto safety.

The processor of the current system also preferably contains at leastone algorithm for substantially identifying or predicting dangeroushealth conditions, more preferably dangerous breathing or other healthconditions based at least in part on the signals received from theconnected sensors of the sensor system. Preferably, the algorithm(s) areadaptive in that they are robust, and can monitor numerous physiologicaland system conditions simultaneously and substantially in real time, andfurther able to react to changes in the numerous conditions in order tomonitor, predict, mitigate, and/or alert the subject or a third partyregarding dangerous breathing or other health conditions. Using thesealgorithms, the processor preferably calculates inhaled and exhaledvolumes of oxygen and carbon dioxide, respiratory periods, oxygensaturation, and other related respiratory metrics. Furthermore, theprocessor may also use these calculated values to determine, identify orpredict a dangerous health or breathing condition such as hypoxia,anoxia, hypo/hyperthermia, hypo/hyperventilation, G-LOC, atelectasis andother similar conditions. Preferably once the breathing sensor systemidentifies or predicts a dangerous breathing condition, the breathingmask sensor system can alert the wearer and/or transmits the biometricinformation to an external monitoring system. One exemplary embodimentof the dangerous condition prediction algorithm that particularlyfocuses on hypoxia, in its simplest form, compares the estimated oxygendemand based on demographic factors and workload to the calculatedoxygen consumption. These quantities are reduced to an estimate ofarterial blood gases, which are thresholded to determine hypoxia riskand alert. However, the algorithms are not a non-invasive replacementfor arterial blood gas measurements. Instead, the algorithm estimates,given previous and current conditions, what the blood gas values willtrend toward in the future. This is accomplished using a physiologicallung model in combination with machine learning models. Specifically,raw signal traces are sliced to represent individual breaths, and eachbreath is reduced, via numerical integration and multiplication, to thegases produced and consumed. These breath-by-breath values are read intothe buffer of a classifier algorithm, which is trained on these data anddirectly measured blood gas data at the end of a 5-minute epoch at agiven altitude. The classifier then uses the respiratory gascalculations to predict subsequent blood gas values. Respiratory and gasexchange patterns that are reflective of healthy or dangerous conditionsmay be analyzed and classified via a linear lung model or, morepreferably, via a machine learning classifier. The machine learningclassifier may be based off of a “strong learning” method, such as anartificial neural network, a support vector machine, or a Bayesclassifier, which may apply training data from a multitude ofindividuals to any user. Alternatively, the classifier may be a “lazylearner” that continuously compares a user's respiratory and gasexchange patterns with the measured blood oxygenation levels, creating aunique algorithm for that particular user that improves classificationaccuracy with continued use. The classifier may rely on a feature spaceselected by known metabolic metrics. Features for a given breath mayinclude the inspiratory volume, the expiratory volume, the CO₂ produced(by mass or analog), the O₂ consumed (by mass or analog), therespiration rate, the breath duration, and the peak negative andpositive mask pressures. Ambient pressure and peak G loads, as well asG-Load integrals under the appropriate time window can also beconsidered for the feature vector. Finally, samples of SpO₂ and heartrate may be included in the feature vector as well. The breath-by-breathmetrics of the feature space most intuitively come from a single breath.However, it may be advantageous to consider multiple breaths at once.These “breath-tuples” may include the features from any discrete numberof breaths, for example from 1 breath to 10 breaths. A certain count ofbreath-tuples can be considered the optimal tradeoff betweenclassification accuracy and time delay. The classifier is preferablytrained to SpO₂ bins, which are sampled from a time-offset SpO₂ trace.The time offset, meant to reflect SpO₂ levels in the future, can rangefrom 30 seconds to 3 minutes.

By way of example of this process, the system may predict the onset ofG-force induced loss of consciousness (G-LOC) based on a series ofmeasurements of ventilation or flow rate of the subject's breath andcarbon dioxide output which allow the system to determine the subject'sbreath rate and type of breathing the subject is performing. The systemcan then differentiate between G-LOC and hyperventilation, both of whichmay exhibit very similar signs and breathing conditions. If the systemdetermines that the subject is about to experience G-LOC, then it caninstruct the user to initiate a pre-determined breathing protocoldesigned to mitigate or prevent G-LOC, specifically where the subjectdecreases the duty-cycle of his or her breathing and uses very short,high flow breaths that counteract the breathing conditions that lead toG-LOC. In another example, the system may monitor and detect theoccurrence of atelectasis, or the collapse, either complete or partial,of the lung or individual alveoli in the lunch, and instruct the user tocough or otherwise alter his or her breathing to force the alveoli backopen.

The system, specifically the sensor module(s), can preferably beutilized to output real-time breathing patterns of the subject. Thesereal-time breathing patterns can be, in turn, used to aid the subject inproper breathing. The breathing patterns and/or warnings orinstructions, can be displayed to the subject via a heads up display toinstruct the subject on a particular breathing pattern that would behelpful for the given circumstances. In addition, the breathing patternscan be stored for later analysis and use whereby an instructor canreview the data and review breathing patterns with the subject.

The algorithm(s) utilized by the present invention are designed toprovide real-time calculations based at least in part on the signalsreceived from the sensor(s) of the system. In many embodiments of thepresent invention, the algorithm(s) utilized employ a series ofequations developed for prediction of Acute Mountain Sickness (AMS) byBurtscher et al., and adapted to operate in real-time. See Burtscher etal., PREDICTION OF THE SUSCEPTIBILITY TO AMS IN SIMULATED ALTITUDE, 12Sleep Breath 103 (2008). AMS is also commonly known as AltitudeSickness, and occurs at high altitudes, typically above 8,000 feet, as aresult of reduced air pressure and decreased oxygen levels at thosealtitudes. AMS is essentially similar to and interchangeable withhypoxia in that they both have the same causes and symptoms. Theequations developed by Burtscher were designed to first evaluate asubject at low altitude, and then subsequently again high altitude, andfor a static comparison to be made between the two measurements orevaluations. However, these equations have been adapted to performreal-time, continued analysis of a subject for the present invention, byconverting them from static equations into time dependent equations formeasuring oxygen saturation response (SpO₂ Response), Hypoxic CardiacResponse (HCR), and Hypoxic Ventilatory Response (HVR). These equationsare as follows:

$\begin{matrix}{{{SpO}_{2}\mspace{14mu}{Response}\mspace{11mu}(t)} = {{{SpO}_{2\mspace{14mu}{High}\mspace{14mu}{Alt}}(t)} - {\overset{\_}{SpO}}_{2\mspace{14mu}{Low}\mspace{14mu}{Alt}}}} & \left. 1 \right) \\{{{HCR}(t)} = \frac{\left( {{{HR}_{{High}\mspace{14mu}{Alt}}(t)} - {\overset{\_}{HR}}_{{Low}\mspace{14mu}{Alt}}} \right)}{\left( {{{SpO}_{2\mspace{14mu}{High}\mspace{14mu}{Alt}}(t)} - {\overset{\_}{SpO}}_{2\mspace{14mu}{Low}\mspace{14mu}{Alt}}} \right)}} & \left. 2 \right) \\{{{HVR}(t)} = \frac{\frac{\left( {{{VE}_{{High}\mspace{14mu}{Alt}}(t)} - {\overset{\_}{VE}}_{{Low}\mspace{14mu}{Alt}}} \right)}{\left( {{{SpO}_{2\mspace{14mu}{High}\mspace{14mu}{Alt}}(t)} - {\overset{\_}{SpO}}_{2\mspace{14mu}{Low}\mspace{14mu}{Alt}}} \right)}}{\left( {{Body}\mspace{14mu}{Mass}} \right)}} & \left. 3 \right)\end{matrix}$Blood Oxygen Concentration Response (SpO₂ Response) is the most basic ofthe metrics used to determine and predict the onset of altitude-relateddangerous breathing or other health conditions such as hypoxia, AMS< andthe like. SpO₂ Response is essentially the real-time measurement of asubject's change in blood oxygen concentration. In equation 1, theoxygen saturation response (SpO₂ Response) as a function of time iscalculated by first measuring the average constant blood oxygensaturation of the subject at low altitude (ground level), and thensubtracting that value from the measured blood oxygen concentration ofthe subject at high altitudes for any given time point. This measurementand comparison can be made repeatedly and substantially continuously toprovide a moment-by-moment profile of the subject's blood oxygensaturation under varying conditions, such as increased altitude, overtime. Hypoxic Cardiac Response (HCR) is a metric which is used todetermine the effect that a decreased level of blood oxygenconcentration has on a subject's heart rate. Equation 2 shows thathypoxic cardiac response is calculated by similarly measuring theaverage constant heart rate and blood oxygen concentration at lowaltitudes (ground level), subtracting those values from their respectivemeasured counterpart values at high altitudes, and then dividing thedifference in heart rate value by the difference in blood oxygenconcentration value. This measurement and comparison can be maderepeatedly and substantially continuously to provide a moment-by-momentprofile of the subject's hypoxic cardiac response at any given point intime, and thus correlated to the altitude at that time. HypoxicVentilatory Response (HVR) is another metric used which relates to theeffect that a decrease in blood oxygen concentration has on a subject'sventilation, or the volume of air moved into and out of the subject'slungs in a given amount of time. Equation 3 depicts the calculation ofhypoxic ventilator response as a function of time. First, averageconstant ventilation (VE—volume of air moved in and out of the lungsover time—typically measured in L/min) and average constant blood oxygenconcentration are measured at low altitudes (ground level). Then,ventilation and blood oxygen concentration are measured repeatedly andessentially continuously at high altitudes, and the average constant lowaltitude measurements are subtracted from their respective high altitudecounterparts. The difference between the ventilation rates is thendivided by the difference between the blood oxygen concentration values,and that product is divided by the subject's body mass. Again, thiscalculation can be performed repeatedly and essentially continuously,thus providing a moment-by-moment profile of the subject's hypoxicventilator response at any given point in time, and correlated to thealtitude at that given time point. Each of these three equations wasadapted to provide a real-time, continuous analysis of the variouseffects and responses the subject's body experiences by measuring therespective values and performing continuous calculations as above. Thisis a significant improvement over the typical method of performingseparate static measurements and comparing the results at a later timeto determine the effect on the subject. The adapted formulas allow forreal-time monitoring, detection, prediction, and mitigation of dangerousbreathing or other health conditions such as hypoxia and AMS.

Alternatively, instead of including a separate processor, the system maycontain electronic components that can perform many of the functions ofthe processor described above. Preferably, these electronic componentscan be miniaturized and/or adapted to fit into a single enclosure orhousing, which can also, in turn, preferably a miniaturized dataacquisition unit. The processor or electronics optionally can compriseone or more electronic components for detecting the physiological signalfrom the sensor(s). While some of the electronic components such as thebattery or antenna may be separate from the other electronic components,and in the case of the antenna may be printed right onto a base orboard, which the electronics optionally are mounted onto. The one ormore electronic components for detecting the physiological signal fromthe at least two electrodes is a wireless device, which most preferablytransmits the physiological signals to a remote receiving unit.Preferably, the one or more electronic components also filter (andpossibly amplify) the detected signal and more preferably convert thisdetected physiological signal, which is in an analog form into a digitalsignal for transmission to the remote receiving unit. The one or moreelectronic components and/or process optionally may be incorporated ontothe facemask or in close proximity to the subject. Further preferably,the one or more electronic components can receive a signal from theremote receiving unit or other remote transmitters. The one or moreelectronic components may include circuitry for but are not limited tofor example electrode amplifiers, signal filters, analog to digitalconverter, RF output antenna, RF input antenna, RF output/input antenna,optical output antenna, optical input antenna, optical output/inputantenna, acoustic output antenna, acoustic input antenna, acousticoutput/input antenna, subcarrier voltage controlled oscillator (VCO),transmitter VCO, tuning crystal, phase-locked loop, frequency selectswitches, a DC power source and combinations thereof. The one or moreelectronic components may comprise one processing integrated circuit,multiple integrated circuits, single function components or combinationsthereof, which can perform all of the necessary functions of detectingthe sensor or physiological signal(s), transmitting a signalcorresponding to the sensor signal(s) to a receiving unit and optionallyreceiving a signal from a remote transmitter. These one or moreelectronic components can be assembled on a printed circuit board or byany other means known to those skilled in the art. Preferably, the oneor more electronic components can be assembled on a printed circuitboard or by other means so its imprint covers an area less than 4 in²,more preferably less than 2 in², even more preferably less than 1 in²,still even more preferably less than 0.5 in², and most preferably lessthan 0.25 in². The one or more electronic components can be furtherreduced into discrete components for inclusion into an integratedcircuit (IC), or more preferably, an application specific integratedcircuit. These integrated circuits may be of any of the type including,but not limited to, analog to digital converters, processors, and othercomponents necessary to lower the cost, reduce the size, weight, and/orpower of the present invention. The present invention preferablyutilizes switched-mode power supplies where possible to increase theefficiency of the system. In particular, the 2.5V and 10V rails areaccomplished via a switched mode power supply and a stacked capacitorconfiguration respectively. These are important to achieve batteryoperation and may not be employed by commercial devices meant to drawpower from a mains outlet.

Preferably, the circuitry of the one or more electronic components isappropriately modified so as to function with any suitable miniature DCpower source. More preferably, the DC power source is a battery. Themost preferred battery of the present invention is zinc-air hearing aidbatteries. Zinc-air hearing aid batteries offer a high energy densityand nearly constant output voltage during discharge, which ispreferable. Additionally, these commercially available batteries arereadily available and inexpensive. Preferably, a three-cell stack ofzinc-air batteries are used, each cell offering a steady 1.2 V, andproducing a stable and reliable 3.6 V. Other types of batteries includebut are not limited to lithium-polymer and lithium-ion batteries,zinc-air batteries, and the like.

Preferably, the circuitry of the one or more electronic componentscomprises data acquisition circuitry further including an electrodeamplifier which detects the sensor signal(s) and integrates the detectedsignal(s) into a single signal and amplifies it to some power level. Thedata acquisition circuitry is designed with the goal of reducing size,lowering (or filtering) the noise, increasing the DC offset rejectionand reducing the system's offset voltages. The data acquisitioncircuitry may be constrained by the requirements for extremely highinput impedance, very low noise and rejection of very large DC offsetand common-mode voltages, while measuring a very small signal ofinterest. Additional constraints arise from the need for a “brick-wall”style input protection against ESD and EMI. The exact parameters of thedesign, such as input impedance, gain and passband, can be adjusted atthe time of manufacture to suit a specific application via a table ofcomponent values to achieve a specific full-scale range and passband.

More preferably, a low-noise, low power instrumentation amplifier isused. The inputs for this circuitry is guarded with preferably, externalESD/EMI protection, and very high-impedance passive filters to reject DCcommon-mode and normal-mode voltages. Still preferably, theinstrumentation amplifier gain can be adjusted from unity toapproximately 100 to suit the requirements of a specific application. Ifadditional gain is required, it preferably is provided in a second-orderanti-alias filter, whose cutoff frequency can be adjusted to suit aspecific application, with due regard to the sampling rate. Stillpreferably, the reference input of the instrumentation amplifier istightly controlled by a DC cancellation integrator servo that usesclosed-loop control to cancel all DC offsets in the components in theanalog signal chain to within a few analog-to digital converter (ADC)counts of perfection, to ensure long term stability of the zeroreference.

Preferably, the physiological signal is converted to a digital form.This can be achieved with an electronic component or processingintegrated circuit through the use of an ADC. More preferably, the ADCrestricts resolution to 12-bits due to the ambient noise environment insuch integrated circuits. Despite this constraint, the ADC remains thepreferable method of choice for size-constrained applications such aswith the present invention unless a custom data acquisition integratedcircuit is used because the integration reduces the total componentintegrated circuit count and significantly reduces the number ofinterconnects required on the printed circuit board, which results insmaller size, weight, and power.

Preferably, the circuitry of the one or more electronic componentscomprises a digital section. Part of this circuitry may include one ormore integrated circuits preconfigured to perform some or all of thedigital processing for use with existing wireless protocols includingbut not limited to wireless local area networks (IEEE 802.11 includingWi-Fi), wireless personal area networks (IEEE 802.15 including Bluetoothand ZigBee), wireless metropolitan area networks (IEEE 802.16) or othersknown to those skilled in the art. More preferably, the heart of thedigital section is the MicroChip™ PIC microcontroller or othercomparable microcontroller including microcontrollers from competingcompanies including Atmel and Texas Instruments. One such alternative isthe STM32F4 series ARM Cortex-M4 microcontroller from STMicroelectronicswhich includes a floating point math core, Digital Signal Processing(DSP) library, and integrates peripherals such as SDIO (SD cards), USB,high speed 12 bit Analog/Digital Converters (ADC), and a large amount ofRAM memory (192 KB). The preferable MicroChip™ PIC 16LC771microcontroller or other comparable microcontroller would containsufficient data and program memory, as well as peripherals, which allowthe entire digital section as well as the ADCs to be neatly bundled intoa single carefully programmed processing integrated circuit, and morepreferably an application specific integrated circuit. Still preferably,the onboard counter/timer sections are used to produce the dataacquisition timer, and can further be used to measure the VCO frequencyand to confirm synthesizer lock. Still preferably, an onboardsynchronous serial port (SSP) is used to control the synthesizer, togenerate a RF data stream, and to communicate with external testequipment. Also preferably, an onboard main oscillator generates notonly the microcontroller clock, but also the reference clock for thesynthesizer. Additional digital outputs are used to control specificfunctions. Still preferably, one ADC input is dedicated to measurementof the VCO tune voltage to allow for automation of the final testing,and a separate function multiplexed onto this same pin allows limiteddirect control of the VCO tune voltage during automated final testing.

The synthesizer can induce distortion in the transmitted digital datawhen the data does not contain exactly equal numbers of ones and zeroesover a prolonged interval. This distortion arises because thesynthesizer sees the modulation as error to be servoed out, and fightsthe modulation as it attempts to steer the VCO back to the nominalfrequency. Preferably, the reference oscillator has the ability tomodulate the reference frequency with any low-frequency content of thefinal transmitted digital data, with one of the results being that thereference and the VCO move in concert during modulation and therefore donot distort the data, and the low-frequency content of the designed datapacket format should result in only minimal distortion. Optionally, thiscapability can be removed to reduce the imprint of the printed circuitboard holding the one or more electronic components.

Preferably, the circuitry for the one or more electronic componentscomprises nonvolatile, rewriteable memory. Alternatively, if thecircuitry for the one or more electronic components doesn't comprisenonvolatile, rewriteable memory then an approach should be used to allowfor reprogramming of the final parameters such as radio channelizationand data acquisition and scaling. Alternatively, other memory formatsmay be used, including, but not limited to external flash memory or aremovable SD card (removable flash storage) to store a configurationparameter file editable as a text file. The entire device can beconnected via USB Mass Storage Device standards to a PC. Withoutnonvolatile, rewriteable memory, the program memory can be programmedonly once. Therefore, one embodiment of the present invention involvesselective programming of a specific area of the program memory withoutprogramming the entire memory in one operation. Preferably, this isaccomplished by setting aside a specific area of program memory largeenough to store several copies of the required parameters. Procedurally,this is accomplished by initially programming the circuitry for the oneor more electronic components with default parameters appropriate forthe testing and calibration of the biometric monitoring system. When thefinal parameters have been determined, the next area is programmed withthese parameters. If the final testing and calibration reveals problems,or some other need arises to change the values, additional variations ofthe parameters may be programmed.

Preferably the circuitry of the one or more electronic componentsincludes an RF, optical and/or acoustic transmitter. Also, preferably,the circuitry includes a custom voltage controlled oscillator (VCO) madeup of discrete electronic components, and a phase-locked loop (PLL)synthesizer built around commercially available electronic components.Additionally, preferably, the whole radio section of the circuitry canbe powered down independently of the digital section components. Stillfurther preferably, the synthesizer is controlled by the firmware viathe SPI bus, and uses a crystal oscillator to derive a precision clock.

In these embodiments, the VCO design is unique in several ways. A bufferis preferably required between the core VCO active element and theantenna, to minimize pulling of the VCO frequency by physical movementat or near the antenna. Still preferably, the VCO itself uses anegative-resistance oscillator configuration. Still preferably, this isa stacked configuration to allow sharing between the VCO and the buffer.Still preferably, this configuration allows for two or more differentconfigurations of the buffer with negligible size impact on the imprintof the circuitry of the one or more electronic components. This type ofdesign can be laid out to allow for two different configurations of thebuffer with a negligible impact on size. In one configuration, the VCOand buffer are in a cascade configuration (common base amplifier), suchthat the buffer provides voltage gain and buffering. In anotherconfiguration, the configuration becomes a common-emitter buffer, withthe potential to allow firmware control of the transmitted power duringPLL lock by reducing the gain of the buffer during lock. Preferably,this capability is provided with no size or power impact in thecommon-emitter configuration and reduces the potential for interferencewith other units during unit startup. On the other hand, the cascadeconfiguration preferably is more resistant to antenna pulling, soprecharge of the tune voltage and careful sequencing and timing of thestartup are required to prevent interference.

Preferably, tuning of the VCO is performed by using a uniquearchitecture that minimizes power consumption while significantlyreducing noise compared to more conventional approaches such as using avaractor to perform tuning in response to an applied voltage.Preferably, in various embodiments of the present invention, the PLLapplies a tuning voltage to the top side of a varactor, reversingbiasing of the varactor to the level required to achieve a desiredoscillation frequency. Conventional designs mix the modulation with thistune voltage to modulate the carrier produced by the VCO. However, thismixing normally requires a summing junction plus a buffer, and thebuffer generates significant 1/F noise, seriously degrading the phasenoise performance of the VCO. In addition, the required swing of themodulation voltage is orders of magnitude smaller than that of the tunevoltage. Preferably in various embodiments of the present invention,only the PLL tune voltage is injected at the top of the varactor, andthe modulation voltage is injected at the bottom of the varactor. Bypre-inverting the modulation voltage, a bias voltage is achieved acrossthe varactor that is the arithmetic sum of the tune voltage and themodulation voltage without the undesirable interactions of theconventional approaches. Because the required swing of the modulationvoltage is very small, a resistive divider can be used as the last stepin applying the modulation voltage, thus keeping the signal amplitudevery large right up until the final division, forcing any accompanyingnoise to also be divided down before application to the varactor. Thisenhances the signal-to-noise ratio in the modulation voltage.Additionally because the required swing is very small, the divisionratio in the final divider is large, allowing for very low current drawwhile still providing extremely low Thevenin equivalent resistance andvery low thermal noise at this sensitive node.

Another feature of the circuitry of the one or more electroniccomponents preferably is an antenna. The antenna, when RF, preferably,is designed onto the upper surface of the base of the biometricmonitoring system and is integrated into the rest of the circuitry. Theantenna can be configured in a number of ways, for example as a singleloop, dipole, dipole with termination impedance, logarithmic-periodic,dielectric, strip conduction or reflector antenna. The antenna isdesigned to include but not be limited to the best combination of usablerange, production efficiency and end-system usability. Preferably, theantenna consists of one or more conductive wires or strips, which arearranged in a pattern to maximize surface area. The large surface areawill allow for lower transmission outputs for the data transmission. Thelarge surface area will also be helpful in receiving high frequencyenergy from an external power source for storage. Optionally, the radiotransmissions of the present invention may use frequency-selectiveantennas for separating the transmission and receiving bands, if an RFtransmitter and receiver are used on the biometric monitoring system,and polarization-sensitive antennas are used in connection withdirectional transmission. Polarization-sensitive antennas consist of,for example, thin metal strips arranged in parallel on an insulatingcarrier material. Such a structure is insensitive to or permeable toelectromagnetic waves with vertical polarization; waves with parallelpolarization are reflected or absorbed depending on the design. It ispossible to obtain in this way, for example good cross polarizationdecoupling in connection with linear polarization. It is furtherpossible to integrate the antenna into the frame of a processingintegrated circuit or into one or more of the other electroniccomponents, whereby the antenna is preferably realized by means of thinfilm technology. The antenna can serve to just transfer biometricmonitoring system data or for both transferring data to and forreceiving control data received from a remote communication stationwhich can include but is not limited to a wireless relay, a computer ora processor system. Optionally, the antenna can also serve to receivehigh-frequency energy (for energy supply or supplement). In anyscenario, only one antenna is required for transmitting data, receivingdata and optionally receiving energy. Optionally, directional couplescan be arranged on the transmitter outputs of the biometric monitoringsystem and/or the remote communication station.

In many embodiments, particularly where the electronic componentsdescribed above are enclosed in a single housing or enclosure creating adata acquisition unit, sensors may be included in the circuitry of theunit, particularly at least one accelerometer. Accelerometers and othersensors included in the electronics unit provide several benefits to thepresent invention. First, the sensor measurements can be used to provideco-registration between the man-mounted (subject-worn) data measurementsystem and any systems that may be vehicle-based or remotely-based. Forexample, accelerometer measurements may indicate a particularly highlevel of g-forces, and the two separate accelerometer measurements—atleast one in the subject's data acquisition electronics enclosure and atleast one for the aircraft—can be used to register the separate datastreams so that they are in-line and synchronized. This synchronizationof data streams can further be aided by inclusion of a real-time clockin the data acquisition circuitry enclosure which can provide asecondary data point to be matched and synchronized with the data filesof other systems such as on the vehicle or remote systems. Suchsynchronization allows for accuracy of measurement both in real-time tohelp detect, prevent and mitigate dangerous conditions, and post-hocanalysis of the subject's condition in order to learn and understandwhat factors might lead to such dangerous conditions. For example, anaccelerometer in the electronic component/data acquisition enclosurefurther can provide a measure of exertional hypoxemia where the systemdetects high g-force conditions and can use that information to helppredict or determine if the subject soon thereafter experiencesexertional hypoxemia based on the increased likelihood of such onsetbecause as a subject experiences such forces and conditions, his or hertolerance to them decreases until given time to completely recover.Therefore, the sensor in the data acquisition electronics can helpprovide the system with data, especially when registered andsynchronized with other sensors, to help predict, detect, mitigate orprevent dangerous breathing or other health conditions.

An additional feature of the present invention is an optionalidentification unit. By allocating identification codes—a subject code(for each subject being monitored), the remote communication station iscapable of receiving and transmitting data to several subjects, and forevaluating the data if the remote communication station is capable ofdoing so. This is realized in a way such that the identification unithas control logic, as well as a memory for storing the identificationcodes. The identification unit of the biometric monitoring system ispreferably programmed by radio transmission of the control charactersand of the respective identification code from the programming unit ofthe remote communication station to the biometric monitoring system.More preferably, biometric monitoring system comprises switches asprogramming lockouts, particularly for preventing unintentionalreprogramming of the biometric monitoring system.

In any RF link, errors are an unfortunate and unavoidable problem.Analog systems can often tolerate a certain level of error. Digitalsystems, however, while being inherently much more resistant to errors,also suffer a much greater impact when errors occur. Thus the presentinvention, when used as a digital system, preferably includes errorcontrol subarchitecture. Preferably, the RF link of the presentinvention is digital. RF links can be one-way or two-way. One-way linksare used to just transmit data. Two-way links are used for both sendingand receiving data.

If the RF link is one-way error control, then this is preferablyaccomplished at two distinct levels, above and beyond the effort toestablish a reliable radio link to minimize errors from the beginning.At the first level, there is the redundancy in the transmitted data.This redundancy is performed by adding extra data that can be used atthe remote communication station or at some station to detect andcorrect any errors that occurred during transit across the airwaves ortransmitted through water. This mechanism known as Forward ErrorCorrection (FEC) because the errors are corrected actively as the signalcontinues forward through the chain, rather than by going back to thetransmitter and asking for retransmission. FEC systems include but arenot limited to Hamming Code, Reed-Solomon and Golay codes. Preferably, aHamming Code scheme is used. While the Hamming Code scheme is sometimesmaligned as being outdated and underpowered, the implementation incertain embodiments of the present invention provides considerablerobustness and extremely low computation and power burden for the errorcorrection mechanism. FEC alone is sufficient to ensure that the vastmajority of the data is transferred correctly across the radio link.Certain parts of the packet must be received correctly for the receiverto even begin accepting the packet, and the error correction mechanismin the remote communication station reports various signal qualityparameters including the number of bit errors which are being corrected,so suspicious data packets can be readily identified and removed fromthe data stream.

Preferably, at a second, optional level, an additional line of defenseis provided by residual error detection through the use of a cyclicredundancy check (CRC). The algorithm for this error detection issimilar to that used for many years in disk drives, tape drives, andeven deep-space communications, and is implemented by highly optimizedfirmware within the biometric monitoring system processing circuitry.During transmission, the CRC is first applied to a data packet, and thenthe FEC data is added covering the data packet and CRC as well. Duringreception, the FEC data is first used to apply corrections to the dataand/or CRC as needed, and the CRC is checked against the message. If noerrors occurred, or the FEC mechanism was able to properly correct sucherrors as did occur, the CRC will check correctly against the messageand the data will be accepted. If the data contains residual errors(which can only occur if the FEC mechanism was overwhelmed by the numberof errors), the CRC will not match the packet and the data will berejected. Because the radio link in this implementation is strictlyone-way, rejected data is simply lost and there is no possibility ofretransmission.

More preferably, the RF link utilizes a two-way (bi-directional) datatransmission. By using a two-way data transmission the data safety issignificantly increased. By transmitting redundant information in thedata from the sensors and electronics, the remote communication stationis capable of recognizing errors and requesting a renewed transmissionof the data. In the presence of excessive transmission problems such as,for example, transmission over excessively great distances or due toobstacles or media that absorbs the signals, the remote communicationstation is capable of controlling the data transmission, or tomanipulate on its own the data emitted by the biometric monitoringsystem. With control of data transmission, it is also possible tocontrol or re-set the parameters of the biometric monitoring system,e.g., changing the transmission channel. This would be applicable forexample if the signal transmitted by the biometric monitoring system issuperimposed by other sources of interference then by changing thechannel the remote communication station could secure a flawless andinterference free transmission. Another example would be if the signaltransmitted by the biometric monitoring system is too weak, the remotecommunication station can transmit a command to the biometric monitoringsystem increasing its transmitting power. Still another example would bethe remote communication station causing the biometric monitoring systemto change the data format for the transmission, e.g., in order toincrease the redundant information in the data flow. Increasedredundancy allows transmission errors to be detected and corrected moreeasily. In this way, safe data transmissions are possible even with thepoorest transmission qualities. This technique opens in a simple way thepossibility of reducing the transmission power requirements of thebiometric monitoring system. This also reduces the energy requirementsof the biometric monitoring system, thereby providing longer batterylife. Another advantage of a two-way, bi-directional digital datatransmission is the possibility of transmitting test codes in order tofilter out external interferences such as, for example, refraction orscatter from the transmission current. In this way, it is possible toreconstruct falsely transmitted data. Due to the safe and effectiveone-way and two-way transmission of the various embodiments of thepresent invention between the biometric monitoring system and the remotecommunication station, the present invention is particularly suitablefor use other locations, such as in a nursing home, for example inmonitoring many patients with respiratory problems.

The remote communication station of various embodiments of the presentinvention can be any device known to receive RF, optical or acousticaltransmissions used by those skilled in the art to receive transmissionsof sensor data from the monitoring system. The remote communicationstation by way of example but not limitation can include acommunications device for relaying the transmission, a communicationsdevice for re-processing the transmission, a communications device forre-processing the transmission then relaying it to another remotecommunication station, a computer with wireless capabilities, a PDA withwireless capabilities, an IPad, a processor, a processor with displaycapabilities, and combinations of these devices. Optionally, the remotecommunication station can further transmit data both to another deviceand/or back to the monitoring system. Further optionally, two differentremote communication stations can be used, one for receiving transmittedphysiological data from the biometric monitoring system and another forsending data to the biometric monitoring system. For example, with thewireless physiological monitoring system of the present invention, theremote communication system of the present invention can be a wirelessrouter, which establishes a broadband internet connection with themonitoring system and transmits the physiological signal to a remoteinternet site for analysis, preferably by the subject's physician.Another example is where the remote communication system is a PDA,computer or cell phone, which receives the physiological datatransmission from the biometric monitoring system, optionallyre-processes the information, and re-transmits the information via celltowers, land phone lines, transmitters or cable to a remote site foranalysis. Another example is where the remote communication system is acomputer or processor, which receives the physiological datatransmission from the biometric monitoring system and displays the dataor records it on some recording medium, which can be displayed ortransferred for analysis at a later time.

Preferably, the remote communication station can pick up and transmitsignals from distances of greater than about 5 feet from the subject,more preferably greater than about 10 feet from the subject, even morepreferably greater than about 20 feet from the subject, still even morepreferably greater than about 50 feet from the subject, still even morepreferably greater than about 200 feet from the subject, and mostpreferably greater than about 500 feet from the subject. The remotecommunication station is used to re-transmit the signal based in partfrom the physiological signal from the biometric monitoring systemwirelessly or via the internet to another monitor, computer or processorsystem. This allows for a third party to review the subjects biometricdata and environmental conditions and if necessary to make adetermination, which could include dispatching help.

Moving now to a description of the figures, FIG. 1 is an illustration ofone embodiment of a breathing mask sensor system for pilots and aircrew.This particular embodiment comprises a breathing mask 10, breathing tube40, inhaled gas sensor housing 15, an inhaled gas sensor 45, flow sensorhousing 30, an exhaled gas sensor housing 20, and an exhaled gas sensor25. Additionally, in this particular embodiment, the flow rate sensorhousing 30 has an embedded temperature sensor housing 35 for a gas flowtemperature sensor (not shown) which may be inserted into the flowsensor housing 30.

The breathing mask 10 in this embodiment is envisioned to be any flightmask commonly used in the art today, whether it be military, combat,commercial, freight, recreational, personal flight, or otherwise. Thepresent invention is intended to operate as a sensor suite and processorsystem which may be adapted easily and readily to fit onto virtually anyexisting or later developed breathing mask. Alternatively, the system isalso envisioned as providing a standalone breathing mask containing thesensor suite and processor, which can be integrated into any existingsystem. Although FIG. 1 depicts a flight mask embodiment, the sensors(exhaled gas sensor 25, inhaled gas sensor 45, temperature and flowsensors not shown) and processor (not shown) are designed to beadaptable with other breathing mask systems as well, such as for divers,firefighters and other first responders, medical breathing masks (e.g.,anesthesia, CPAP), and the like. The breathing mask 10 is constructed offlexible, non-irritant materials commonly known to those of skill in theart for producing such masks.

The breathing tube 40 is similarly intended to be of any type presentlyknown to those skilled in the art or later developed for use with suchbreathing mask systems. The breathing tube 40 is constructed ofresilient yet flexible materials capable of bending, flexing andstretching while remaining able to return to its original shape, andwithout breaking, cracking, or otherwise becoming damaged. Typical hosesknown in the art today are made of materials such as rubber, silicone,soft plastics, or the like. The breathing tube may be modified tocontain any wires within its structure or inside the tube itself toprevent such wires from getting tangled. The breathing tube extends fromthe on board oxygen generation system (OBOGS) or other similar breathingmix generator (not shown) to the breathing mask 10, and provides apathway for the breathing mix to reach the pilot or other aircrewwearing the mask.

Many embodiments employ not only a primary OBOGS, but also a backupoxygen supply or delivery system (BASS) (not shown). Preferably, thebackup oxygen supply or delivery system operates in an automated orsemi-automated manner. With respect to the BASS, automated means that ifthe primary OBOGS fails, or the system detects a dangerous breathingcondition that the OBOGS cannot mitigate or counteract, the BASS wouldautomatically initiate its function to supply additional or supplementaloxygen or breathing mix of gases to the subject. Semi-automatedoperation of the BASS means that when the primary OBOGS fails or thesystem detects a dangerous breathing condition that cannot be mitigatedor counteracted, a warning or alert is sent or communicated to thesubject or a third party who initiates operation of the BASS to deliveradditional or supplemental oxygen or breathing mix of gases to thesubject.

The present embodiment depicts a flow sensor housing 30 at the distalend of the breathing tube 10. The flow sensor housing 30 is designed toconnect or be adaptable to all breathing tubes presently known to thoseskilled in the art or later developed for use with such breathing masksystems. The flow sensor housing 30 contains a central chamber (notshown), extending through the length of the flow chamber housing,through which the breathing mix flows from the breathing mix generator(not shown), through the breathing tube 40, to the breathing mask 10,for the subject to breathe. The central chamber of the flow sensorhousing 30 is adaptable to include one or more sensors. Preferably, inembodiments where the flow sensor chamber is included, at least one flowsensor is contained within the central chamber of the flow sensorhousing 30. Flow sensors may be used to measure the rate at which gas isflowing, volume of gas, and the like.

Additionally, several embodiments include a temperature sensor (notshown) within the flow sensor housing 30. The temperature sensor istypically a thermistor, mounted in the temperature sensor housing 35.The thermistor temperature sensor is mounted into the temperature sensorhousing 35 with the resistive, measurement end of the thermistorextending through ports in the side of the flow sensor housing 30 andinto the central chamber of the flow sensor housing. In theseembodiments, there is preferably at least one flow separator disc (notshown) positioned perpendicular to the flow of the breathing mix ofgases (and thus perpendicular to the central chamber of the flow sensorhousing). More preferably there are at least two flow separator discswith a predetermined amount of space between them. The measurement endof the thermistor, when placed into the central chamber of the flowsensor housing 30 is either on the proximal side of the preferably oneflow separator disc, or in between the preferably two flow separatordiscs. The flow separator disc(s) operate to cause disturbances in theflow of the breathing mix gases traveling toward the subject, and tocause the mix to separate into various streams of gas. This separationallows the thermistor to register and measure a more accuratetemperature reading of the gas mixture as a whole, and prevents falsereadings based on a condensed or unmixed burst of a particular gas.

Once the breathing mix passes through the flow sensor, and into andthrough the breathing tube 40, it travels toward the mask 10 where itwill be breathed in by the subject. To get to the subject, in someembodiments, the breathing mix of gas mast pass through an inhaled gassensor 45 which is contained in an inhaled gas sensor housing 15. Muchlike the flow sensor housing 30, the inhaled gas sensor housing 15 isdesigned to be resilient and adaptable to fit virtually all presentlyknown breathing tube and breathing mask systems, as well as those laterdeveloped. The inhaled gas sensor housing 15, attaches at one end to thebreathing tube 40, and to the breathing mask 10 at the other end. Thus,as the breathing mix exits the breathing tube 40, it passes through theinhaled gas sensor housing 15 and then into the breathing mask 10.Again, much like the flow sensor housing 30, the inhaled gas sensorhousing may contain any type or combination of sensors. The most commontypes of sensors which may be used here are oxygen sensors, carbondioxide sensors, and temperature sensors. However, many other types ofsensors are contemplated for use in the inhaled gas sensor housing,including, but not limited to, sensors for measuring volatile organiccompounds, hydrocarbons, pressure, flow rates, and the like. The sensorsmay be miniaturized to fit into a single inhaled gas sensor housing 15,or multiple such housings may be attached in series, whereby the gasflows through each of them in turn en route to the breathing mask 10.Each sensor that is used records its particular signal as the breathingmix flows through or over the sensor and into the breathing mask 10.

Once the breathing mix enters the breathing mask 10, it is inhaled bythe subject. At least one check valve (not shown) is placed in the airflow pathway which prevents additional gas from entering the mask untilafter the subject has exhaled his or her breath. Alternatively, at leasttwo check valves are placed in or on the inhaled breath mechanism,possibly attached to the inhaled gas sensor housing 15, and in or on theexhaled breath mechanism, possibly attached to the exhaled gas sensorhousing 20, and operate to cause the exhaled air to leave the breathingmask only through the exhaled breath housing and sensor. The check valveprevents the inhaled and exhaled gases from mixing, and thus providingskewed measurements from the exhaled gas sensor 25. The check valve (notshown) may further include a flow sensor therein to provide datapertaining to gas flow to the sensor module in integrated mask systems.

Internal to the breathing mask, many other sensors are contemplated foruse. For example, a microphone(s) may be included which, in combinationwith the check valve, are used to provide a noise canceling functionwhen the subject is talking or communicating. At least one electrode,preferably a dry surface electrode, may be included, either in the maskor otherwise on the subjects body. Dry surface electrodes may be used todetect and measure electroencephalography (EEG), electrocardiography(ECG), electromyography (EMG), electrooculography (EOG), heart rate, orother physiological signals which may be used to help determine thesubject's physiological state.

Once the subject exhales, the expired breath passes through at least oneexhaled gas sensor 25, which is seated in an exhaled gas sensor housing20. Similar to the inhaled gas sensor housing 15, the exhaled gas sensorhousing 20 is designed to be resilient and adaptable to fit virtuallyall presently known breathing tube and breathing mask systems, as wellas those later developed. The exhaled gas sensor housing 20 may containany type or combination of sensors. The most common types of sensorswhich may be used here are oxygen sensors, carbon dioxide sensors, andtemperature sensors. In this particular embodiment, the exhaled gassensor is a carbon dioxide sensor. The carbon dioxide sensor is placedinto a specially adapted and innovative carbon dioxide sensor housing20, to be adapted to the exhaled breath side of any such breathing maskpresently known to those skilled in the art, or later developed. Otherembodiments may include other types of sensors for use in the exhaledgas sensor housing 20, including, but not limited to, sensors formeasuring volatile organic compounds, hydrocarbons, pressure, flowrates, and the like. The sensors may be miniaturized to fit into asingle exhaled gas sensor housing 20, or multiple such housing may beattached in series, whereby the gas flows through each of as it isexhaled and exits the breathing mask 10. Each sensor that is usedrecords its particular signal as the breathing mix flows through or overthe sensor and into the ambient air.

The sensor or sensors used in the above system, measure their particularobject as the gas flows through or over the sensor. These measurementsare recorded substantially in real-time per each breath. By real time,it is intended that the sensor preferably records the measurement andtransmits the signal to the processor (not shown) within 10 seconds ofthe gas passing through or over the sensor. More preferably, the sensorrecords the measurement and transmits the signal to the processor within5 seconds of the gas passing through or over the sensor. Even morepreferably, the sensor records the measurement and transmits the signalto the processor within 3 seconds of the gas passing through or over thesensor. Still more preferably, the sensor records the measurement andtransmits the signal to the processor within 1 seconds of the gaspassing through or over the sensor. Yet more preferably, the sensorrecords the measurement and transmits the signal to the processor within500 milliseconds of the gas passing through or over the sensor. Even yetmore preferably, the sensor records the measurement and transmits thesignal to the processor within 100 milliseconds of the gas passingthrough or over the sensor. Even still more preferably, the sensorrecords the measurement and transmits the signal to the processor within50 milliseconds of the gas passing through or over the sensor. Mostpreferably, the sensor records the measurement and transmits the signalto the processor simultaneously as the gas passes through or over thesensor.

The processor (not shown) collects and correlates the signals receivedfrom the sensors. The processor contains and employs an algorithm (notshown) which uses the signals received from the sensors to calculatevarious measurements and metrics based on the signals from the sensors(see FIG. 7). Those measurements and metrics are then parsed to identifya dangerous physiological condition that is presently occurring, or morepreferably to predict the onset of such a condition. When the processorand algorithm calculate that such a dangerous condition is occurring, orsoon will occur, a warning or alert is sent out. The warning or alertmay be sent to the subject or wearer of the mask, to a third person,such as a remote monitoring system (e.g., aircraft carrier flight deckmonitor, dive master, another pilot or team member), or to an internalor external system, such as a closed-loop control system for regulatingthe breathing mix delivered to the subject. The warning or alert servesto put the receiver of the alert on notice that the subject isexperiencing, or is about to experience a dangerous breathing condition,and allows that person to either come to the subjects aid, or to helpprevent the onset of more serious conditions.

Some embodiments comprise a closed-loop breathing mix delivery system(not shown). Such embodiments take the measured and calculated valuesbased at least in part on the signals received from the sensor orsensors contained in the particular embodiment, and determine theappropriate mix of gases for the subject that would either help saidsubject recover from a presently occurring dangerous breathingcondition, or prevent an oncoming predicted dangerous breathingcondition. Such embodiments would take the measured and calculatedvalues and automatically adjust the breathing mix to the optimum volumesof each mixed gas and provide this new mix through the system describedabove to the subject. The sensor measurements would each occur again,and the closed-loop system would continue to adjust the breathing mixaccordingly to those continuously measured and calculated values.

Still other embodiments may employ an oxygen or breathing mix dosingsystem (not shown). The dosing system is primarily used for systemscomprising a reserve or backup oxygen or breathing mix gas supply. Inthe event of the primary or main oxygen or breathing mix supply systemfailing (e.g., failure of the OBOGS in a fighter jet), a reserve orbackup system would then begin to supply the required gases for thesubject to maintain a healthy breathing condition or status. Such asystem may be automated (e.g., ABOS—automated backup oxygen system) andkick in automatically upon failure of the primary delivery system orloss of ambient or cabin pressure, or may be semi-automated where thesubject or a third party triggers the system to operate based onperceived or measured need of additional oxygen or breathing mix. Mostoften, such reserve or backup systems comprise a reserve gas tank with afinite amount of gas, though they may comprise a backup OBOGS or othergeneration system. The oxygen or breathing mix dosing system helps toextend the life of the reserve gas supply and thus maximize thelikelihood that the subject has enough oxygen or breathing mix to returnto safety, and mitigates or prevents the onset of dangerous breathing orother health conditions. Preferably, the system uses the sensors andcomponents described herein to measure and monitor the subject'smetabolic rate. The metabolic rate is then used to determine therequired dose of oxygen or breathing mix necessary to sustain thesubject's healthy breathing status. This system automatically increasesor decreases the amount of the reserve or backup gas supply that isdelivered to the subject based at least in part on the sensormeasurements and the measured or calculated metabolic rate. AS thesubject's metabolic rate increases and demand for oxygen or breathingmix increases, the system increases the amount of the reserve gassupplied, and vice versa. Thus, by providing only the amount of oxygenor breathing mix necessary to maintain safe status of the subject, theamount of the reserve gas supply utilized is minimized, and the life ofthe reserve is extended. This system allows for extended missions whennecessary, as well as maximizes the likelihood that the subject will beable to return to safety upon failure of the primary gas supply system.

FIG. 2 depicts an alternative embodiment whereby the exhaled gas sensorhousing with dust cover 50 and the exhaled gas sensor 55 areparticularly adapted for oxygen sensors, as opposed to carbon dioxidesensors as in FIG. 1. Again, the same process and alternativeconfigurations may be applied to the embodiment in FIG. 2 allowing forthe system to measure only exhaled partial pressure of oxygen, inhaledpartial pressure of oxygen, or any combination of other gases andmeasurements based on the sensors chosen.

One additional feature depicted here is a microphone 60. This figuredepicts the external portion of the microphone 60, which has the actualaudio sensor (not shown) on the interior of the breathing mask 10. Oneor more microphones may be incorporated into the breathing mask 10. Theprimary microphone allows the subject to communicate with other teammembers or remote monitoring stations and personnel. However, at leastone additional microphone may be included for noise cancellationpurposes. Traditionally, when the subject of such a breathing masksystem speaks, the inspired and expired air inherent to speaking causesdisruptions, or noise, in the inhaled and exhaled gas sensormeasurements. Providing at least one additional microphone allows thesystem to calibrate the measurements along with the check valve (notshown) to differentiate between true inhaled or exhaled breaths, andinspired or expired air resulting from speech. This allows the system toperform a noise canceling function and minimize speech related artifactsfrom the sensor measurements.

This microphone 60 is typically a powered device requiring a powersupply to function. In some embodiments, the power supply (not shown)for the microphone may additionally be used to supply power toprocessing components (PDAU—not shown) that are miniaturized andintegrated in-line with the breathing system, such as into the CRU (notshown).

FIG. 3 depicts an alternative view of the mask embodiment in FIG. 2 fromthe reverse side of the breathing mask 10. Here, the subject places hisor her mouth and nose into the breathing mask 10, situating the maskinto its natural position. The interior of the mask may contain amicrophone, thermistor, and/or pressure transducer 60 is situatedimmediately near the subject's mouth. If a microphone is included, itmay be used for communication purposes, and/or for providing a noisecanceling function to prevent noise in the sensor recordings resultingwhen the subject speaks. Additional microphones may be provided insidethe breathing mask 10 to allow one for communication, and at least onefor noise canceling functions. If a thermistor is included, it may beused to measure in-mask temperature, inhaled breath temperature, exhaledbreath temperature, or the like. Similarly, if a pressure transducer isincluded, it may be used to measure in-mask pressure.

The breathing tube 40 connects into the inhaled gas sensor housing (notshown). Here, the breathing mix of gases crosses over the inhaled gassensor (not shown) which is situated inside or attached to the inhaledgas sensor housing (not shown). The sensor, again, may be any one of avariety of sensors, including but not limited to oxygen sensors,temperature sensors, carbon dioxide sensors, volatile organic compoundsensors, hydrocarbon sensors, pressure sensors, flow sensors,accelerometers, gyroscopes, microphones, electrodes, and the like, orany combination thereof. Also, the sensors may be sufficientlyminiaturized to fit into a single housing, or may be attached in seriesallowing the gas to flow over or through each sensor in turn as itpasses from the breathing tube 40 into the breathing mask 10.

As the breathing mix of gases passes over the inhaled gas sensor(s) (notshown), it enters the mask 10 where it is inhaled by the subject. Acheck valve (not shown) stops the flow of air and prevents the subject'sexhaled breath from returning through the inhaled gas sensor (not shown)and into the breathing tube 40 against the pressurized flow. Instead,the subject's exhaled breath passes through the exhaled gas sensor (notshown) which is situated inside or attached to the exhaled gas sensorhousing 50. As the exhaled breath passes through the exhaled gas sensor(not shown), the sensor records its measurements and transmits them tothe processor for analysis.

FIG. 4 depicts a particular embodiment of the present invention forpilots and aircrew, and more particularly military and fighter pilots.The subject or pilot 65 dons the breathing mask 10 which typically isattached to a helmet. The subject 65 enters the aircraft 80 and situateshim or herself into the cockpit. In this figure, a representativefighter jet is depicted, with the cockpit door 70 opened above thesubject 65, and the cockpit windshield 75 in front. On board such anaircraft, an OBOGS or other breathing mix generator (not shown) isincluded which provides a pressurized gas flow of breathable gases forthe subject to breathe when operating the aircraft. That breathing mixof gases travels through the breathing tube 40 and into the breathingmask 10 as previously described. In many embodiments, before thebreathing mix enters the breathing mask 10 for the subject to breathe,it passes through an inhaled gas sensor (45, not depicted in the presentfigure) which is situated inside of or attached to an inhaled gas sensorhousing 15. The inhaled gas sensor records its measurements andtransmits those measurements via a signal to the processor (not shown).As the subject breathes in the breathing mix and then exhales his or herbreath, a check valve or valves, as described above, direct the exhaledbreath to exit through the exhaled gas sensor 55 which is situatedinside of or attached to the exhaled gas sensor housing 50, and which isattached to the breathing mask 10. Again, both the inhaled and exhaledgas sensors may be of any type previously described, or any combinationthereof, and may be sufficiently miniaturized to fit into a singlehousing, or may be attached in series or in separate housings.

Preferably, the sensor housings for both inhaled and exhaled gas sensorsare designed to be easily adaptable to be fitted or retrofitted ontovirtually all existing breathing masks known to those in the art, aswell as those later developed. The sensor housings are intended to beable to attach to any such mask and thus provide any of the describedsensors and their accompanying measurements to virtually any breathingmask system. One non-limiting example of an adaptable housing attachmentmechanism is to provide a threaded ring which fits securely into theopening of a bear mask on either the inhaled or exhaled side, and towhich the sensor housing also securely attaches. The sensor housing maythen be secured into position with respect to the threaded ring by meansof set screws. This allows for a different threaded ring to be used forthe particular mask employed, while still using the same sensor housing.The set screws allow the sensor housing to be positioned in a particularorientation that is convenient to the subject and does not encumber hisor her movements or comfort, while still ensuring the sensor housing'ssecure placement into the threaded ring and attachment to the breathingmask. Those skilled in the art will understand and appreciate other suchadaptable attachment means which provide a secure attachment to multiplestyles, forms, and types of masks.

FIG. 5 depicts another embodiment of the present invention where thesensor suite is deployed in a diver's breathing system. This particularembodiment depicts a military combat diver, utilizing a completelyenclosed, recirculated breathing system. However, the invention iscontemplated for use with all types and styles of diver breathingsystems, including military, commercial, and recreational divers.

In this embodiment, the diver 80 dons his or her diving suit (not shown)which includes a diving breathing mask 95. The diver's breathing systemincludes a tank (135, not shown in this figure) or several tanks, whichprovide the oxygen and other breathing gases (breathing mix) for thediver. Those gases are pressurized and travel from the tank(s) towardthe diver's breathing mask 95 through a breathing delivery tube 85. Thistube is similarly constructed to the breathing tube in the abovedescribed aircrew embodiments to be resilient and flexible, and to beable to withstand extreme pressures and conditions. In some embodiments,as the breathing mix passes through the delivery tube 85, it enters intothe diver's breathing mask 95 by passing through an inhaled gas sensorhousing 100 which is integrated into the breathing delivery tubeattachment mechanism that connects the delivery tube 85 to the diver'sbreathing mask 95. In those embodiments, an inhaled gas sensor 105 issituated inside of attached to the inhaled gas sensor housing 100similar to the aircrew embodiment above. As the breathing mix passesover the inhaled gas sensor 105, the sensor records its measurement andtransmits to the processor 125.

The breathing mix then enters the diver's breathing mask 95 and thediver inhales said mix. At least one check valve 120 is used to preventthe exhaled breath from reentering the breathing delivery tube 85, andinstead forces that exhaled breath to exit through the exhaled gassensor housing 110, exhaled gas sensor 115 situated inside of orattached to the exhaled gas sensor housing 110, and into the breathingreturn tube 90. As the exhaled breath passes through or over the exhaledgas sensor 115, that sensor too records its measurement and transmitsthat measurement via a signal to the processor 125 for analysis. Theexhaled breath then travels through the breathing return tube 90 andreturns to the tank(s) (135, not shown in this figure) where it isremixed for recirculation.

The completely closed-loop recirculation system depicted in the presentembodiment is typical of military combat diver systems where no exhaledbreath is expelled in order to prevent the creation of gas bubbles inthe water around the diver which may give away the diver's position.Such closed-loop recirculation systems may also be used commercially orrecreationally as well. Alternatively, in a non-recirculating system,the exhaled breath, after it passes through the exhaled gas sensor 115and housing 110, would not necessarily be returned through a breathingreturn tube 90, but could be expelled into the water.

Again, as in the previously described embodiments, the sensors recordtheir measurements and transmit the measurements to the processor via asignal. The system may include sensors on the torso, face mask, andbreathing tube, and electronics box and warning LED. Such sensors mayinclude, but are not limited to oxygen sensors, temperature sensors,carbon dioxide sensors, volatile organic compound sensors, hydrocarbonsensors, pressure sensors, flow sensors, accelerometers, gyroscopes,microphones, electrodes, and the like. The sensors may communicate theirsignals to the processor via wired or wireless means 130. The processor125 comprises an algorithm which receives the sensor signals, and usesthe measured values to calculate a plethora of metrics related to thediver's biometric breathing conditions, health, environment, metabolicconditions, and the like. The algorithm then correlates the measuredvalues and calculated values to determine whether the diver 80 is in asafe, healthy condition, undergoing a dangerous breathing condition(such as hypoxia), or to predict if the diver is likely to or about toexperience such a dangerous breathing condition. If the diver 80 isexperiencing, or is predicted to experience such a dangerous breathingcondition, the processor 125 then transmits a warning signal or alert.This warning or alert may be transmitted to the diver 80, and may be inthe form of a visual signal integrated into the diver's breathing mask95 or equipment, an audio signal broadcast through the diver'scommunication system, or a mechanical signal such as a vibration. Thewarning or signal may also be transmitted to a third person, such asanother diver or team member, a submerged vehicle in the vicinity (e.g.,diver delivery vehicle or manned vessel), or to the surface such as to adive master. In any of these events, the third person would be alertedthat the diver 80 is in trouble and may be incapacitated, and thus caninitiate a rescue procedure to recover the diver 80 before he or shebecomes unable to recover and drowns. Alternatively, a closed-loopsystem may be provided whereby when a dangerous condition is identifiedor predicted, the system itself recalibrates the breathing mix of gasesin order to try and counteract the condition or prevent it fromoccurring. The various types of warnings and alerts may also be used inconjunction with each other providing multiple levels of safety for thediver 80.

FIG. 6 depicts a diver 80 in action employing the system of the presentinvention. Here, the diver 80 can be seen as wearing an entire divingsystem comprising breathing gas tank(s) 135, diving mask 140, breathingmask 155, and the onboard processor 125. The breathing gas tanks mix anddeliver breathing gases through the breathing delivery tube (85, notshown in this figure) to the diver's breathing mask 155 for the diver tobreathe. The diver's breathing mask 155 comprises the exhaled gas sensorhousing 110 and exhaled gas sensor 115, and in some embodiments theinhaled gas sensor housing 100 and inhaled gas sensor 105, allpreviously described. Further included in the present embodiment, thediver 80 is wearing a diver's mask with a heads up display 141. Thismask with heads up display comprises visual indicators which may be usedas part of the warning and alert system for identifying and predictingdangerous breathing or other health conditions such as hypoxia. Theheads up display operates, by way of non-limiting example, as follows.The sensors record their measurements as the breathing mix or exhaledbreath flows over or through the particular sensors employed in theembodiment. As above, these sensors may include, but are not limited to,oxygen sensors, temperature sensors, carbon dioxide sensors, volatileorganic compound sensors, hydrocarbon sensors, pressure sensors, flowsensors, accelerometers, gyroscopes, microphones, electrodes, and thelike. As the sensors record their measurements, they transmit a signalrelated to those measurements to the processor 125 by wired or wirelesscommunication methods.

The processor 125, comprising an algorithm, receives the signals andrecords the measurements to which the signals relate, and uses thosemeasurements to calculate still further biometric data 145 related tothe diver's health, metabolic state, respiratory conditions,environment, and the like. When the measured values and the calculatedmetrics indicate that the diver 80 is experiencing a dangerouscondition, or predicts such a condition, the processor 125 thencommunicates a signal to the diver's mask heads up display 141. Theheads up display 141 then displays the warning to the diver 84 by anynumber of means, including, but not limited to flashing or blinkinglights, preferably LEDs, an auditory signal or message, a scrollingtextual alert, or the like. Additionally or alternatively, a warningsignal or alert may be sent to an external underwater transceiver 150which in turn relays the message to other divers or team members in thevicinity, to a manned or unmanned vehicle in the area which may try toextract the diver, or to a topside (out of water) vessel or person, suchas a dive master who may help initiate preventative or rescue proceduresto recover the afflicted diver.

FIG. 7 depicts a flow chart representing the inputs to the processorcomprising an algorithm and the metrics that may be measured orcalculated by the system and used for making a determination as to thesubject's health status or danger, and in predicting the onset ofdangerous conditions such as hypoxia.

Traditional systems for measuring and monitoring the status of a subjectin the applications for which this invention is intended typically relysolely on pulse oximeters 160, which provide a non-invasive method formeasurement of oxygenation, or oxygen saturation (SpO₂) 175 of asubject's blood. Pulse oximeters are generally optical sensors wherebytwo different wavelengths of light, typically red light and infraredlight, are passed through a portion of the subject's body and receivedby a photodetector on the other side. Each of the different wavelengthsof light has a different absorption rate for oxygenated ornon-oxygenated blood. The subject's blood oxygen saturation isdetermined as a function of the absorbance of these wavelengths of lightas indicating the ratio of oxygenated versus non-oxygenated hemoglobin.Pulse oximeters may be used to not only measure oxygen saturation, butalso heart rate (in beats per minute, or BPM) 170.

These pulse oximeter measurements (oxygen saturation and heart rate) maythen be used to calculate several other useful metrics as well. From acombination of saturation and heart rate, the subject's Hypoxic CardiacResponse 270 may be calculated. Hypoxic cardiac response 270 isessentially the effect that hypoxic conditions have on the subject'scardiac function. As oxygen saturation decreases, cardiac function tendsto increase as well. The pulse oximeter's 160 oxygen saturation 175measurement may also be used to calculate SaO₂ response 275 and HypoxicVentilatory Response 280. SaO₂ response 275 is a measure of thepercentage of hemoglobin molecules in the blood that are oxygenated andis relevant to how that percentage changes under hypoxic conditions.Hypoxic ventilatory response (HVR) 280 is the effect wherebyventilation, or the rate at which gas enters and leaves the lungs,increases as a result of hypoxic conditions.

All of the above are common, standard measurements and calculationswhich are capable of being acquired through sole use of a pulseoximeter, and all of which are useful in detecting or measuring thesubject's status. The present invention, however, goes beyond mere pulseoximeter measurements and calculations. The present invention mayinclude a pulse oximeter as one of the sensors utilized in the system.Thus, the present invention may perform the standard measurements andcalculations above. Additionally, the present invention employs at leastone gas sensor 165, and in many embodiments several additional gassensors 165 which allow the system to obtain more measurements,calculate many more biometrics, and overall provide a more robust andaccurate system with predictive capabilities rather than justidentification.

Once such gas sensor 165 is an exhaled breath oxygen sensor. Preferably,this exhaled breath oxygen sensor measures the partial pressure ofoxygen 180 of an exhaled breath, typically measured in mmHg. In thefigures described above, particularly FIG. 2 and FIG. 3, the exhaled gasoxygen sensor is depicted as reference 55. Some embodiments may utilizea pulse oximeter (not shown) which also measures oxygen saturation. Thepulse oximeter may be a traditional such sensor clipped on to thesubject's finger; however, such pulse oximeters may be troublesome asobstacles to the subject who is typically performing potentiallydangerous activities (e.g., pilots, divers, first responders, etc.).Therefore, it is preferable that the system utilizes a pulse oximeterthat is attached, affixed to, or applied in the subject's ear cup. Suchsystems allow the subject to use his or her hands in a free,unencumbered manner while still obtaining oxygen saturation measurementsvia pulse oximeter. Further, the pulse oximeter in such embodiments maybe the sole or primary oxygen sensor used, but also may be a secondaryor backup oxygen sensor.

Another gas sensor 165 which may be utilized with the present inventionis an exhaled breath carbon dioxide sensor which is used to measure thepartial pressure of carbon dioxide 185 in the subject's exhaled breath,typically measured in mmHg. The exhaled gas carbon dioxide sensor isdepicted in FIG. 1 as reference 25

Additional sensors are also potentially included, such as to measureambient pressure (in mmHg) 190 and exhaled gas flow rate (L/min) 195.Ambient pressure refers to the pressure immediately surrounding thesubject. For example, with respect to most fixed wing aircraft (e.g.,fighter jets), the ambient pressure would be cabin or cockpit pressuresurrounding the pilot; for divers, ambient pressure would be thesurrounding water Although these are the only measured values depictedin the figure, the invention is intended to use numerous other types ofsensors, and combinations thereof, to measure many other values. Forexample, oxygen and carbon dioxide sensors may be included on the inhaleend of the breathing mask in order to measure the respective partialpressures of those gases inhaled. Temperature sensors may be included oneither the inhaled or exhaled breath side of the mask to determinetemperature of the gases being breathed. Such temperature measures canbe used to calculate or estimate the subject's core body temperature.Sensors may be included to detect and measure the presence of volatileorganic compounds (e.g., jet fuel) which are chemicals with a high vaporpressure under ordinary conditions, and which can be harmful to thesubject if his or her breathing mix becomes contaminated with suchcompounds. Hydrocarbon sensors may be included to detect and measure thepresence of hydrocarbons which can also be harmful to the subject ifthey contaminate the breathing mix. Flow sensors may be included tomeasure the rate of gas flow, either inhaled or exhaled. This flowsensor is placed at the distal end of the breathing tube 40 and can beused to measure the rate of breathing mix flow as it enters thebreathing tube 40. Accelerometers and gyroscopes may be included inorder to detect and measure the subject's body position and orientationat a given time or during a particular event or stage. As noted above,microphones may be included not only for communication, but also fornoise canceling functions. Electrodes may also be included to recordphysiological signals from the subject's body. Preferably, dryelectrodes are used. Such electrodes may be used to record EEG, ECG,EMG, EOG signals, and the like. All of the above sensors may be includedand provide valuable measurements which can be used to calculate furtherbiometrics to help evaluate the subject's status and predict the onsetof dangerous breathing or other health conditions such as hypoxia.

In the present embodiment, both the exhaled breath partial pressure ofoxygen 180 and the ambient pressure 190 measurements are used tocalculate further values including the exhaled oxygen mole fraction 200,the exhale volume of oxygen (L) 205, and the exhaled end tidal oxygenlevel (mmHg) 210. The exhaled oxygen mole fraction 200 and exhaledoxygen volume 205 values are essentially a conversion of the oxygenpartial pressure 180 measurement and ambient pressure 190 into a volumeor amount calculation of oxygen in the exhaled breath. Exhaled end tidaloxygen 210 is another value representing the partial pressure of oxygen,but at the end of the subject's tidal (normal) breath. Each of thesevalues represent the amount of oxygen being expired from the subject ina different manner, and particularly when coupled with a known inspiredamount of oxygen, due to a calculated breathing mix, can be used todetermine and predict dangerous breathing or other health conditions forthe subject.

Also in the present embodiment, both the exhaled partial pressure ofcarbon dioxide 185 and the ambient pressure 190 are used to calculatethe exhaled carbon dioxide mole fraction 215, the exhaled carbon dioxidevolume (L) 220, and the exhaled end tidal carbon dioxide level (mmHg)225. Additionally, the exhaled carbon dioxide mole fraction can be usedto calculate the subject's carbon dioxide production (L/s) 230. Theexhaled carbon dioxide mole fraction 215 and exhaled carbon dioxidevolume 220 values are essentially a conversion of the carbon dioxidepartial pressure 185 measurement and ambient pressure 190 into a volumeor amount calculation of carbon dioxide in the exhaled breath. Exhaledend tidal carbon dioxide 225 is another value representing the partialpressure of carbon dioxide, but at the end of the subject's tidal(normal) breath. Carbon dioxide production 230 is effectively ameasurement of how much carbon dioxide the subject is exhaling as aresult of his or her breathing process. Each of these values representthe amount of carbon dioxide being expired from the subject in adifferent manner, and particularly when coupled with a known inspiredamount of carbon dioxide, due to a calculated breathing mix, can be usedto determine and predict dangerous breathing or other health conditionsfor the subject.

Still in the present embodiment, the exhaled gas flow rate measurementis used to calculate the inhaled breath volume (L) 235, and thesubject's ventilation (L/min) 240. The inhaled breath volume is a basicmeasure of the volume of gas (breathing mix) inhaled by the subjectduring each breath. Ventilation, as discussed above, is the rate atwhich gas enters and leaves the lungs. Ventilation, in turn, can also beused to calculate the subject's hypoxic ventilatory response, thus notrequiring a pulse oximeter and its accompanying oxygen saturationmeasurement to calculate this metric.

Many other values may be calculated from the measured sensor values orfrom the other calculated values that are not directly tied to any oneparticular sensor, measurement, or calculated value. For example,inhaled breath time (sec) 250, exhaled breath time (sec) 245,respiratory rate (breaths per min) 255, and breath time ratio 260 canall be calculated by general metrics regarding the subject's breathing.These values in particular are useful in identifying or predictinghyperventilation. Additionally, these values may help determine whensuffocation may be occurring. In this context, suffocation particularlyrefers to the instance where pressure and ambient forces (e.g., g-forceor depth pressure) force the exhale valve of the breathing mask shut andthus prevent the subject from drawing a breath due to the check valve.One other, innovative metric that is calculated in the presentembodiment is the standard oxygen absorption (L/min) 285. Oxygenabsorption is a measure of the amount of oxygen the subject absorbsduring a breath. However, standard oxygen absorption is a standardized,normalized measurement of the amount of oxygen absorbed in a breath forthe subject based on the altitude (for pilots and aircrew) or depth (fordivers). This is an important feature because this measurement allowsthe system to more accurately predict the subject's breathing conditionsand to predict the onset of potentially dangerous conditions.

FIG. 8 is a flow chart depicting the process of sending a warning oralert based on the measured and calculated values. The figure generallyfollows the flow of the breathing mix of gases from generation by theOBOGS or other breathing mix generator to exhalation by the subject.Sensor measurements are split off in order as the measurements are takenand transmitted.

First, the OBOGS or other breathing mix generator system mixes andpressurizes the breathing mix, forcing the mix to enter the breathingtube 290. The breathing mix then travels through the breathing tubetowards the subject's breathing mask. In some embodiments, a flow sensoris attached to the distal end of the breathing tube. In otherembodiments, the flow sensor further contains other sensors, which maybe any of those previously described. In the particular embodimentportrayed here, the flow sensor also contains a temperature sensor.Thus, the breathing mixture enters the flow meter and passes through295. As the breathing mix passes through, the flow sensor andtemperature sensors measure their respective values and transmit asignal 300 based on those measurements to the processor for analysis.

Once the breathing mix passes through the flow and temperature sensor,it continues through the breathing tube and toward the subject'sbreathing mask. In some embodiments, the breathing tube attaches to thebreathing mask by means of a coupling inhaled gas sensor housing whichcontains at least one inhaled gas sensor. The inhaled gas sensor(s) maybe of any type of variety previously described. The breathing mix exitsthe breathing tube, and passes through or over the inhaled gas sensor305, and enters the breathing mask. Much like the flow sensor above, asthe breathing mix passes through or over the inhaled gas sensor(s), theinhaled gas sensor(s) make the appropriate measurements and transmit asignal 310 based on those measurements to the processor for analysis.

Once the breathing mix passes into the breathing mask, the subjectinhales the breathing mixture 315, and then subsequently exhales his orher breath 320. A check valve is generally employed to prevent reverseflow of breathed gases and to prevent an excess build-up of gases in themask which could create difficulties in breathing for the subject.Further, the check valve helps force the exhaled breath out through theexhaled gas sensor housing which contains at least one exhaled gassensor. Again, the exhaled gas sensor may be any of the type previouslydescribed, or a combination thereof. The exhaled breath passes over orthrough the exhaled gas sensor 325 and the exhaled gas sensor makes itsrespective measurement. Once the measurement is made, the sensortransmits a signal based on the measured value 330 to the processor foranalysis.

The processor receives each of the sensor signals and correlates thosesignals to the measured values on which they are based. The processorcomprises an algorithm which takes the sensor measured values andcalculates a number of additional metrics (see FIG. 7). The measuredvalues and calculated metrics are then combined and correlated by thealgorithm. The resulting calculated biometric data 335 represents thesubject's health status, breathing information, environmental data, andthe like, all depending on the number and combination of sensors used.The algorithm then determines, based on the resultant biometric data,whether the subject is experiencing a dangerous condition, such ashypoxia, suffocation, hyperventilation, etc., or if the data predictsthat such a dangerous condition is about to or soon to occur to thesubject. In the event of an identified or predicted dangerous condition,the processor, further comprising a transmitter, sends out a warning oralert to send help to the subject who may be unable to respond, or tohelp prevent the dangerous condition from occurring. One type of warningor alert that may be sent out is to the subject himself or herself 340.Alternatively, the warning or alert may be sent to a third person 345,such as a team member, remote monitor, or an overseer (e.g., adivemaster) who can then try to give aid to the subject. Still anothertype of warning or alert might be to a closed-loop system which thenautomatically recalibrates 350 the breathing mix of the subject's airsupply in order to counteract the existing dangerous condition orprevent the predicted dangerous condition from occurring.

In some closed-loop embodiments, systems may be employed which, uponreceiving an alert or warning from the biometric monitoring system,automatically take control of the subject's vessel or equipment. Suchsystems are particularly useful for the fighter pilot embodiments wheredangerous conditions may render the subject incapacitated and in severedanger of crashing and death. Such a closed loop system would allow anauto-pilot feature to keep the aircraft aloft while the subject isrestored to capacity. A similar system may be employed where the alertor warning is sent to a third party, thus giving the third party controlof the subject's vessel or equipment (e.g., remote control flight). Inunderwater embodiments, particularly in military, commercial, andrecreational embodiments, the alert or warning may activate an automaticsafety mechanism which may not only help locate the subject, but mayalso engage a mechanism to bring the subject to the surface for easierextraction and rescue. Many such applications are contemplated in thevarious embodiments of the present invention.

FIG. 9 is a graph representing hypoxia detection response of the presentinvention (9A—ΔPPO₂) versus that of a traditional pulse oximeter(9B—SpO₂) system. As can be seen from the graphs, the present inventionwas able to detect and identify the onset of hypoxia in this particularpatient thirty seconds earlier than the traditional pulse oximeter-onlysystem. In the applications envisioned for this invention, to improvesafety, thirty seconds is a vast window of time. The faster response ofthe present invention over traditional systems represents the ability tonot only more rapidly identify and respond to existing hypoxicconditions, but also presents the opportunity to predict and preventdangerous conditions before they occur.

FIG. 10 depicts cross-sectional views containing greater detail of (A)one embodiment of an oxygen sensor used with the present inventions, and(B) one embodiment of a carbon dioxide sensor used with the presentinvention. FIG. 10A depicts an embodiment of an oxygen sensor 400. Theparticular oxygen sensor 400 comprises a photodiode 405 which may be ofany type currently known to those of skill in the art, such as a PINphotodiode, or later developed. This photodiode 405 emits a lightsource, preferably in the visible blue spectrum, through aruthenium-based dye 415 and thus excites the ruthenium dye. Thephotodiode's 405 emitted light is first passed through an opticallong-pass filter 410 designed to attenuate shorter wavelengths and allowthe longer wavelengths to pass through the filter and then into andthrough the ruthenium-based dye. The optical filter 410 may also be ofany type presently known to those of skill in the art, or a type laterdeveloped, but in the particular embodiment is a colored glass filter.The now-excited light exits the dye 415 and enters the flow channel 425,and is in the orange spectrum rather than blue. While in the flowchamber, the light collides and interacts with the air, and morespecifically the oxygen contained in the flow chamber 425. Oxygeninterferes with the excitation of the ruthenium-based dye andeffectively acts to quench the intensity of the light emission whilesimultaneously increasing the fluorescence lifetime. Thesecharacteristics, intensity and fluorescence lifetime, are indicative ofthe rate at which oxygen collides with the ruthenium-based dye, and thiscollision rate is then used to calculate and determine the partialpressure of oxygen in the air or breath in the flow chamber 425. Thelight passes through the chamber 425 and is detected by another diode onthe other side of the flow chamber. This diode may again be of any typeor variety currently known or later developed, but in this particularembodiment depicted, it is a laser diode. Additionally, the oxygensensor 400 comprises a port 427 for installation of a thermistor (notshown). The thermistor is used to measure the temperature of the air orbreath in the flow chamber 425, and to thus allow the system to providetemperature compensation which further allows for the calculation anddetermination of the partial pressure of oxygen, which is a function ofboth the rate of collision between oxygen and the ruthenium dye, andtemperature.

FIG. 10B depicts one embodiment of a carbon dioxide sensor 500. Thecarbon dioxide sensor 500 comprises an array of infrared LEDs 505 whichemits infrared light of a known wavelength and amplitude, preferably ina square wave, that is focused on a detector, in this case an infraredphotovoltaic detector 520. As the array of infrared LEDs 505 emits theinfrared light, the light passes through at least one coated lens 510,travels through the air or breath flow where the light collides withcarbon dioxide molecules in the breath, and is collected by an infrareddetector 515. The light signal, altered by the absorption of some lightby the carbon dioxide molecules, is collected and measured such that thechange in the amplitude of the waveform is corresponds to theconcentration of carbon dioxide in the breath or air. Preferably, theinfrared detector(s) 515 is temperature controlled in order to preventcondensation on the sensor components and pressure drift of the sensor,and to maintain proper calibration of the measurements.

FIG. 11 depicts one embodiment of a Portable Digital Analysis Unit(PDAU) for processing sensor data and performing the system'smonitoring, prediction, mitigation and alert functions. The PortableDigital Analysis Unit 600 is preferably constructed to be small,relatively lightweight, and thus easily and readily able to be carriedby subject or stowed in his or her equipment, gear, clothing, orelsewhere one or in immediate proximity to the subject. Preferably, thePDAU 600 is stored in a pocket or compartment in the subject's clothingsuch that the subject does not have to actively carry or maintain thePDAU's 600 presence, and the PDAU 600 can remain with the subjectperforming the continual analysis of his or her breathing conditions.The PDAU 600 may comprise a visual indicator such as a screen 605 fordisplaying information (such as physiological measurements andcalculations, battery status, and the like) or providing a visual alertor warning regarding dangerous breathing and other physiologicalconditions. The PDAU 600 also comprises a connection panel 610,portrayed in the callout in greater detail, which allows the varioussensors to be connected to the PDAU 600 for signal input. In theparticularly depicted embodiment, the connection panel 610 comprisesconnection points for sensors including one carbon dioxide (CO₂) sensor615, a flow sensor 620, and two pressure sensors 625 and 630. Theconnection panel 610 further comprises a power switch 635 for turningthe unit on and off; a status light 640 for providing a visual indicatorof whether the unit is on or off, and optionally if the unit isfunctioning properly (e.g., by displaying different colored lights toindicate status, mode or operation); and an analog out port 645 forallowing the PDAU to be connected to an external device (not shown) fortransferring physiological measured and calculated data for separateanalysis and review, or to other devices for display (e.g., an externalmonitor). This image merely depicts one embodiment of the presentinvention where the PDAU and system are specifically designed to onlymeasure carbon dioxide, flow, and two pressures either all together, orin some combination. Many other embodiments existing allowing formeasurement with all of the sensors described herein, in numerouscombinations.

As noted above, preferably the electronic components contained withinthe PDA are miniaturized in order to decrease the size and weight of thesystem, and thus make it less cumbersome to the user. Miniaturizedcomponents allow for a much smaller enclosure to be used where thecomponents are consolidated together. The PDAU can also be formed intodifferent shapes as opposed to the depicted rectangular box, and can beadapted to be integrated into other components of the system. Forexample, in at least one embodiment, the electronics components can besufficiently miniaturized and adapted to be integrated into the CRUmodule or other inhaled regulator fitting, thus eliminating the need fora completely separate PDAU. Or, more preferably, the centralized PDAUcan be eliminated, and instead the electronic and processing componentscan be separated and integrated into the sensor housings, either on theinhaled- or exhaled-sides, or both. For example, various embodiments mayutilize sufficiently miniaturized electronics components, integratedinto the sensor housing on either or both sides, wherein a separateprocessing component receives the signal solely from the sensor(s) withwhich it is integrated, is powered by either a local, similarlyintegrated power source or by connection to the vehicle power system,and performs all necessary data collection and processing functions forthe given sensors, then transmits and/or stores that data accordingly,while an entirely separate miniaturized set of electronic componentsperforms the same functions for the sensor(s) on the other side.Preferably, the electronics in most embodiments are sufficientlyminiaturized to be portable, and perhaps modular. Another optionaladvantage to the integration of electronics components into the in-lineCRU module or other inhaled regulator is that the electronic componentscan receive power from the on-board, or vehicle mounted, power supplysystem, rather that requiring a battery. Removal of the battery allowsfor significant reduction in size and weight of the system.

FIG. 12 depicts one embodiment of the electronics board for the PortableDigital Analysis Unit. The PDAU electronics board 700 comprises theelectrical components for receiving signals from the various sensors(not shown) of the system, and using those sensor signals thatcorrespond to physiological conditions of the subject to monitor,predict, mitigate, and warn of occurring or impending dangerousbreathing or other physiological conditions. Many embodiments of thePDAU electronics board 700 comprise a visual display 705 for displayinginformation (such as physiological measurements and calculations,battery status, and the like) or providing a visual alert or warningregarding dangerous breathing and other physiological conditions. In theparticularly depicted embodiment, the display comprises an LCD screenfor providing messages which may be in the form of text, blinking orflashing lights or colors, or any other variety of message or indicatorwhich may be conveyed by such displays. The depicted embodiment furthercontains a connection point for a thermistor 710 by which saidthermistor may be connected to the board 700, thus allowing the systemto take temperature measurements in accordance with the description ofvarious temperature recordings herein. The board 700 further comprises aconnection for an air flow sensor 715 for connecting and receivingsignals from an air flow sensor. An analog to digital (A/D) converter720 is also included for converting the analog signals received directlyfrom the sensors into a digital format which can be used by the system'salgorithm(s) to perform the necessary calculations. The system ispreferably capable of being both self-powered by means of a batteryand/or externally powered for tethered or more permanent applications.

FIG. 13 presents data from an experiment simulating a steady, gradualincrease in altitude wherein blood oxygen concentration response (SpO₂Response) (13A), Hypoxic Cardiac Response (HCR) (13B), and HypoxicVentilatory Response (HVR) (13C) were all calculated on a continualbasis to determine the response to simulated altitude.

FIG. 14 presents data from an experiment simulating both gradual andmore drastic, or near immediate changes in altitude wherein blood oxygenconcentration response (SpO₂ Response)) 14A), Hypoxic Cardiac Response(HCR) (14B), and Hypoxic Ventilatory Response (HVR) (14C) were allcalculated on a continual basis to determine the response to simulatedaltitude.

FIG. 15 depicts a comparison of data collected from a typical bloodoxygen concentration (SpO₂, measured in %) sensor alone and the presentinvention's suite of measurements used for calculating a subject'spartial pressure of oxygen (PPO₂, measured in mmHg). As a generaloverview, the graph depicts the time delay between the times when eachmeasurement method detects that a dangerous breathing or otherphysiological condition is occurring. The first phase 750 of theexperiment involved taking measurements and monitoring the subject'sstatus while increasing, or simulating an increase in altitude. Both thetraditional blood oxygen concentration 755 and the present invention'spartial pressure of oxygen measurements and calculations 765 aresubstantially steady indicating a stable subject status. After a certainaltitude or simulated altitude is reached, however, the two measurementssystems begin to diverge when a dangerous breathing or otherphysiological condition becomes imminent 760. At approximately 713seconds into the experiment, the present invention's partial pressure ofoxygen 765 metric begins to rapidly decrease indicating a drasticdrop-off in the subject's PPO₂. The PPO2 metric 765, according to theprogrammed algorithms indicates at around 735 seconds that a dangerousbreathing or other physiological condition is, in fact, beginning tooccur. It is not until approximately 794 seconds that the blood oxygenconcentration metric 755 actually indicates that such a condition isoccurring. The subject's condition becomes very dire and potentiallylife threatening 770 at approximately 760 seconds into the experiment.Thus, it can be seen from this data that a traditional blood oxygenconcentration measurement 755 does not adequately detect a dangerousbreathing or other physiological condition, until significantly later intime than when the condition becomes dire (approximately 34 seconds inthis particular data set). Conversely, the present invention's partialpressure of oxygen metric 765 begins to indicate that the subject mayexperience a dangerous breathing or other physiological conditionsignificantly early compared to when the condition becomes dire (in thedepicted data set, approximately 25 seconds prior to the conditionbecoming dangerous, and perhaps as early as about 47 seconds inadvance). In other words, the present invention's partial pressure ofoxygen metric 765 can provide an accurate detection of such a dangerouscondition, but more importantly may be able to predict the onset of sucha condition, and allow the subject or the system to mitigate theseverity and/or prevent the condition from occurring at all. To completethe comparison, there is a substantial and significant time delay 775between the present invention's partial pressure of oxygen metric 765,and the traditional blood oxygen concentration measurement's detectionsof a dangerous breathing or other physiological condition—blood oxygenconcentration was between 60 to 80 seconds slower than the partialpressure of oxygen metric. Therefore, the present invention presents asignificant improvement over traditional methods for detecting suchdangerous conditions, and further provides the ability to potentiallypredict and mitigate and/or prevent such conditions from occurringaltogether.

FIG. 16 depicts the measurement and data flow of an embodiment of thepresent invention utilizing at least one depicted oxygen sensor. In thisparticular embodiment, the Portable Digital Analysis Unit (PDAU) 805outputs a signal 810 that drives the LED emitter 815 of the oxygensensor 800. The LED drive signal 810 of the depicted embodiment isoutput as a square whereby the LED emitter 815 is caused to emit ameasurement light pulse with known attributes. The blue light emittedfrom the LED 815 passes through a lens coated with ruthenium dye whichis excited by the blue light and passes light through in the orangespectrum, which then passes through the air flow 825, on either inhaledor exhaled side depending on where the oxygen sensor 800 is mounted. Asthe orange light passes through the air flow, it collides with oxygenmolecules in the airflow, which interferes with the excitation of theruthenium dye and quenches the intensity of the light. After passingthrough the airflow, the light that passes through is collected by thephotodiode 830 and this measurement signal is amplified by a signalamplifier 835. This amplified measurement signal is then transmittedback to the PDAU 805 in the form of a response signal 840 thatrepresents the changed intensity of the excited light as a result of theconcentration of oxygen molecules in the air flow. The response signal840 is then processed by the electronic components of the PDAU 805 inorder to translate the signal 840 into an actual measurement for theconcentration of oxygen.

FIG. 17 is a flow chart depicting various components and subsystems ofone embodiment of the processing circuitry and/or Portable DigitalAnalysis Unit (PDAU) present invention and the interaction andinformation flow between the components. The figure depicts several maingroupings of PDAU components or subsystems including a microcontroller900, a power management system 905, an internal sensor suite 910, aconnections system 915, and an input and user interface section 920. Themicrocontroller 900, as described herein, can be any type or variety ofmicrocontroller, processor or other processing component that is capableof receiving various input signals and implementing algorithms toprocess the data as desired. The power management system 905 comprisesthe power source (for example a rechargeable battery), a monitor totrack the power currents within the system, and a regulator to controlthe power provided to the various components of the system, and inparticular the microprocessor 900 PDAU components. The power managementsystem outputs the power and command signals to the microprocessor 900to control the operation of the PDAU. The internal sensor suite 910 cancomprise any sensors that might be included in the PDAU as describedherein, including, as depicted, accelerometers, pressure sensors andtemperature sensors. The internal sensor suite for the PDAU providesdata corresponding to the condition and environment of the PDAU and itscomponents, and allows for coordination between various data streams(e.g., between the PDAU and vehicle data systems), as described above.The connections system 915 allows and provides a point for theprocessing circuitry/PDAU of the subject-worn monitoring system to beconnected to and interface with a vehicle (e.g., aircraft, submarine,helicopter, etc.). Through the connections system 915, the many sensorsand data streams of the vehicle-based measurement systems can input datainto the PDAU and those measurements can be taken into account in theprocessing of subject data to give a more complete picture of thesubject's condition based on all environmental factors. The userinterface section 920 provides the interaction points for the subject oranother user to interact with the PDAU, whether to input data orcommands, to view or other forms of interaction with the unit. Also,through the user interface section, a user may install or removeremovable memory for data transfer, or connect the unit to an externalsystem for data transfer.

FIG. 18 depicts a model of an aircraft or other vehicle breathing gassupply system with optional oxygen sensors integrated with or attachedto various subsystems to monitor oxygen at various points. In many suchenvironments, an OBOGS 1000 is the initial phase of generating breathinggas for the subject. The OBOGS 1000 typically comprises at least two bedor media exchange chambers, such as molecular sieves, (not shown) whichcontain a medium that siphons out nitrogen from breathing gas that ispassed through the sieve, and thus increases the concentration of oxygenin the output gas as it leaves the sieve. Typically, the sieves operatein alternating fashion such that when the first sieve is used for apredetermined amount of time, the OBOGS 1000 then switches to the secondsieve to remove nitrogen and increase oxygen concentration of the outputbreathing gas. The problem with such OBOGS systems is that it is notactually known what the oxygen concentration is as the output breathinggas leaves each sieve. These systems are typically calibrated based onsea-level conditions where it is known that each sieve can reach a knownoxygen concentration after a certain amount of time. However, thesecalculations do not account for the changes in circumstances underactual use conditions—such as changes in temperature, pressure,moisture, and the like. Therefore, the present invention optionally addsat least one sensor or sensor bank 1005 (preferably including at leastan oxygen sensor) to the OBOGS system in order to actually measureoxygen concentration of the output breathing gas. Thus, the gas outputfrom the OBOGS 1000 has a known oxygen concentration which helps thesystem and the subject to better monitor and control breathingconditions in order to mitigate and/or prevent the onset of dangerousbreathing conditions. Sensors or sensor banks 1005 can be added to theOBOGS 1000 in numerous ways. At least one sensor or sensor bank 1005 maybe added to the OBOGS output port, at least one sensor or sensor bank1005 may be added to each molecular sieve (not shown) contained in theOBOGS 1000, or multiple sensors or sensor banks 1005 may be located atany combination of such locations. The more sensors that are used, themore information the system has regarding the oxygen concentration alongthe pathway.

Once the oxygenated breathing gas is output from the OBOGS 1000, it maypass into a plenum 1010 which serves as a reserve tank to storeoxygen-rich breathing gas. The plenum 1010 is another location where anoptional sensor or sensor bank 1015 (preferably including at least oneoxygen sensor) may be added. Sensors or sensor banks 1015 located on orwithin the plenum 1010 provide a measure of the oxygen concentration ofthe reserve gas stored in the plenum 1010 and provides a checkpointalong the breathing gas pathway which can help determine if thebreathing gas is compromised or contaminated, or otherwise being alteredon the way from the OBOGS 1000 to the subject.

As the breathing gas cycles through the plenum and towards the subject,it may be measured by an oxygen monitor 1020 integrated into the vehiclesystem which helps to monitor the oxygen content of the breathing gas.Vehicle-mounted oxygen monitors typically include at least one oxygensensor for monitoring the oxygen concentration of the breathing gas, andif the oxygen concentration is too low, for example based on a thresholdthat may be set based on the subject or on a particular mission orfunction, can issue a warning indicating that the oxygen level is toolow. Such a warning may prompt the user to initiate mitigationtechniques to avoid dangerous breathing conditions, or may triggerautomated mitigation systems for providing more oxygen to the subject.The breathing gas passes from the plenum 1010 through an oxygenregulator 1025 which serves to provide the breathing gas at conditionsthat are conducive to subject breathing, that is, at an adequatepressure.

The next component through which the breathing gas passes is anintegrated terminal block and/or CRU 1030. The integrated terminal block(ITB) and/or CRU 1030 is designed to receive breathing gas from at leastone of several sources and direct that breathing gas towards thesubject's breathing mask 1050. In the presently depicted embodiment, theITB and/or CRU 1030 coordinates the breathing gas traveling from theOBOGS 1000 through the reserve plenum 1010, as well as substantiallypure oxygen that can be provided from the emergency oxygen system (EOS)1040. The EOS 1040 can be activated when the system determines that thesubject is not receiving enough oxygen and is exhibiting signs ofdangerous breathing conditions. The system can alert the subject toactivate the EOS 1040 or, in some embodiments, can automaticallyactivate the EOS 1040 without the need for subject initiation. In eitherscenario, the breathing gas mix that initiated with the OBOGS 1000and/or the emergency oxygen supply from the EOS 1040 enter into inletports on the ITB and/or CRU 1030 to be directed towards the subject'sbreathing mask. The EOS 1040 may also optionally comprise one or moreoxygen sensors in order to measure and monitor the oxygen concentrationof the gas contained therein. Although EOS 1040 (and related automatedbackup oxygen systems (ABOS)) contain typically near pure oxygen,sensors contained in these subsystems allows the system to check forcontamination or other problems that may affect the gas supplied to thesubject. Additionally, other sensors may be included in place of or inaddition to oxygen sensors in any of the locations shown in this figure.For example flow, pressure and/or temperature sensors may be included tomonitor each of their attendant conditions of the gas at the particularlocation at which they are placed. Preferably, the system can not onlyactivate such oxygen sources or systems when necessary, but deactivatethem when they are no longer needed, thus conserving the remainingoxygen in the event it is needed later.

The ITB and/or CRU 1030 can be either component separately, but ispreferably a single integrated unit. In some embodiments, a sensor suite(not shown) can be attached to the proximal end of the ITB and/or CRU1030 such that the breathing gas exiting the ITB and/or CRU 1030 can bemonitored and assessed by the various sensors. Alternatively, andperhaps preferably, the ITB and/or CRU 1030 can comprise integratedsensors or sensor banks 1035, including oxygen sensors, carbon dioxidesensors, pressure sensors, temperature sensors, flow sensors, and thelike. Given that the ITB and/or CRU 1030 is the last component thebreathing gas must pass through prior to reaching the subject'sbreathing mask 1050, the sensors or sensor banks 1035 of the ITB and/orCRU 1030 provide the important role of measuring and monitoring theconditions of the breathing gas, including oxygen concentration, beforeit reaches the subject. The breathing gas then passes through the ITBand/or CRU 1030 and any sensors or sensor banks 1035 that are includedin the particular embodiment, and travels to the subject's breathingmask 1050, which preferably contains at least one sensor or sensor bank1055, but which may preferably comprise multiple oxygen sensors (e.g.,one on the inhaled side and one on the exhaled side) as well as one ormore the other various sensor types described herein. The breathing mask1050 sensors or sensor banks 1055 may be individually attached ormounted to the mask, or may be contained in a sensor module (not shown)that can be mounted onto the mask 1050 or integrated into the mask 1050.The sensors or sensor banks 1055 on or integrated with the subject'sbreathing mask 1050 serve to measure and monitor the breathing gas onthe inhaled side and/or on the exhaled side, depending on theembodiment, in order to determine the various metrics calculated by thesystem pertaining to the subject's breathing conditions. With thevarious levels of sensors provided throughout the breathing gas pathway,the system can monitor the content and conditions of the breathing gasin order to determine if and when dangerous breathing conditions mightarise in order to mitigate and/or prevent such conditions, as well as todetermine where the problem might be arising in order to address thecause and further mitigate or prevent the onset of dangerous breathingconditions.

FIG. 19 presents two separate views of internal components of opticalsensors, and particularly oxygen sensors as described herein. Though thedepicted components are taken from the described oxygen sensors, thecomponents can be used to enhance the efficiency of most optical sensorsby slightly altering the way in which the components are situated in thegiven sensor. FIG. 19A depicts a top view of several internal componentsof the optical sensor, particularly the fluorescence excitationcomponent and light channel through which the breathing gas and lightpass. A fluorescent surface 1100 is located within the sensor such thatlight is emitted from a light source (see 1140 of FIG. 19B) at a knownwaveform, wavelength and frequency. Simultaneously, gas, in this casethe breathing gas of the system, enters the sensor through at least oneinlet port 1110. The breathing gas may enter the sensor through theinlet port 1110 either by the force of gradient pressure where the flowof the gas pushes the breathing gas through the inlet port 1110 whilethe gas that flows around the sensor pulls the breathing gas into theinlet port 1110 while passing the side vent ports 1115. Any one or moreof the inlet port 1110, outlet port 1120, and/or side vent port(s) 1115may additionally be adapted to be used as a pressure tap(s) 1130.Alternatively, the breathing gas may be actively pumped into the inletport 1110 via a gas pump (not shown). Ultimately, the gas leaves thesensor via an outlet port 1120. As the breathing gas enters and passesthrough the interior chamber of the sensor, the emitted light passesthrough the breathing gas and strikes the fluorescent surface 1100,becoming excited, and reflecting back from the fluorescent surfacetowards a photodiode or photodetector (not shown). As the excited lightreflects off the fluorescent surface, it typically scatters in manydirections. The present invention employs an optical cone 1105,surrounding the fluorescent surface 1100. The optical cone 1105preferably comprises a reflective surface on the interior of the sensorwhich serves to gather the scattered reflected excited light andredirect it towards the photodetector or photodiode. Accordingly, morelight is detected by the photodetector or photodiode and the sensorserves to operate more efficiently by receiving a greater percentage oflight to measure. This system further extends the life of thefluorescent dye by reducing the amount of emitted light required toobtain accurate measurements. It can be noted that the fluorescentsurface may be a coated surface within and integrated into the sensor,or may be a removable and replaceable puck or other such component thatcan be replaced when the life of the dye is exhausted, thus eliminatingthe need to replace an entire sensor.

Another advantage of the present invention is the ability to thermallycontrol the conditions of the sensors. In the depicted embodiment, theentire optical cone 1105 and fluorescent surface 1100, amongst othercomponents not depicted, are covered or coated in a thermodynamicallyinsulating layer 1125 which prevents heat exchange between the sensorand the ambient environment. Preferably, the interior of the sensor,particularly the optical cone which can extend for a portion or all ofthe stack distance between the emitter/detector and the fluorescentsurface 1100 is thermodynamically conductive such that the optical cone1105 and the breathing gas in the chamber of the sensor aresubstantially the same temperature. This temperature control eliminatesseveral variables from the sensor system, and helps prevent moisturebuild up within the sensor. Thus, the sensor operates more efficientlyand consistently with fewer opportunities for incorrect or alteredmeasurements.

FIG. 19B depicts a cross-sectional view of the same sensor withadditional components. In this view, the fluorescent surface 1100 issituated at the bottom, receiving light emitted from the light source1140 at the top of the sensor unit. The optical cone 1105 surrounds theentire interior chamber of the sensor, including the fluorescentsurface, and optionally extending the entire stack distance from thefluorescent surface to the photodetector or photodiode 1155. Gas entersthe interior chamber of the sensor again either by differential pressuregradients through the at least one inlet port 1110 and by virtue of apulling effect as passing gas flow draws gas through the side vent ports1115, or by active pump into the inlet port 1110, and exits through theoutlet port 1120. Again, any one or more of the inlet port 1110, outletport 1120, and/or side vent port(s) 1115 may additionally be adapted tobe used as a pressure tap(s) 1130. Thus, light is emitted from the lightsource 1140 at a known waveform, wavelength and frequency, passingthrough the gas in the sensor chamber; the light strikes the fluorescentsurface 1100 and reflects back up towards the photodetector orphotodiode 1155. As the light reflects off of the fluorescent surface,it is scattered, but it strikes the reflective surface of the opticalcone 1105 and is directed toward the photodetector or photodiode 1155,thus allowing more of the light to be collected by the photodetector orphotodiode 1155. Also, the sensor is preferably thermodynamicallyinsulated via an insulating layer 1125 which prevents heat exchangebetween the sensor and the ambient environment while the interior of thesensor is thermodynamically conductive to maintain a substantiallyconstant and consistent temperature between the gas and the sensorcomponents.

FIG. 20 depicts a general schematic of OBOGS systems operating through afirst bed or exchange media chamber. Inlet gas 1200 enters the systemfrom any source to which the OBOGS is attached, such as aircraft orvehicle (not shown). A control valve 1205 corresponding to the first bedor exchange media chamber 1210 remains open allowing the feed air 1200to flow into the first bed or chamber 1210. A second control valve 1240corresponding to the second bed or chamber 1230 is closed such that thefeed air passes to the first bed or chamber 1210 but open to allow ventgas 1245 to pass through and be vented from the system. Though only twobeds or chambers 1210, 1230 are depicted, any number of beds or chambersmay be connected in this manner and the system can cycle through each ofthe beds or chambers, regardless of how many, based on availability andreadiness to remove target gas (typically nitrogen) from the feed air1200. Media in the first bed or chamber 1210 begins to adsorb a targetgas, generally nitrogen, from the feed air 1220, while allowing the gasto pass through now containing a higher concentration of oxygen as aresult of the removed nitrogen or other target gas. Typical OBOGSoperate to switch between beds or chambers 1210, 1230 typically on atimed basis. This time is based on known target gas adsorption rates atground level under controlled conditions, and according to the amount oftime the media in the bed or chamber 1210, 1230 would take to becomesaturated with the target gas. Based on these known adsorption rates,the system is set to switch from the first bed or chamber 1210 to thesecond bed or chamber 1230, or to any other bed or chamber in theseries, in order to allow the oxygen rich gas from the first bed orchamber 1210 to pass through as breathing gas to the subject 1220 whileallowing the second bed or chamber 1230, or another bed or chamber inthe series to be operational in adsorbing the target gas from the feedair 1200. When the media in the first bed or chamber 1210 is full or theallotted time passes, the control valves switch accordingly to allow theinlet gas 1200 to feed into the second bed or chamber 1230 or anotherbed or chamber in the series, while the first bed or chamber begins tovent 1245 the adsorbed target gas. The present invention adds at leastone sensor or sensor bank 1215, 1235 to the beds or chambers 1210, 1230,preferably on the outlet of the bed or chamber, where the at least onesensor or sensor bank on each bed or chamber preferably comprises atleast one oxygen sensor. The addition of these sensors or sensor banks1215, 1235 allows the system to monitor the gas in each bed or chamber1210, 1230. By virtue of the sensor(s) or sensor bank(s) 1215, 1235, thepresent invention can monitor the quality and content of the gas outletfrom the bed or chamber 1210, 1230 and determine when the active bed orchamber is operating inefficiently by outputting gas that perhaps doesnot have as much of the target gas removed as when the bed or chamberfirst became operational. This might indicate that the media in thegiven bed or chamber is becoming saturated. Therefore, the system canintelligently switch between beds or chambers, rather than doing so on astrictly time basis. These sensor(s) or sensor bank(s) 1215, 1235 thusallow the system to operate at optimal efficiency, without switchingbetween beds or chambers prematurely or too late, and thus provide theoptimum breathing gas to the subject 1220 at all times.

It will be apparent to those skilled in the art that variousmodifications and variations can be made to the present inventionwithout departing from the spirit and scope of the invention. Thus, itis intended that the present invention cover the modifications andvariations of this invention provided they come within the scope of theappended claims and their equivalents.

The invention claimed is:
 1. A breathing mask sensor system foridentifying or predicting dangerous health conditions comprising: abreathing mask; at least one subject-mounted sensor, the sensor adaptedto measure partial pressure of oxygen within the mask in real time andto produce a signal corresponding to said partial pressure of oxygen,the sensor comprising a light source, a glass longpass filter, a surfacecoated in fluorescent dye, a photodiode, a frustoconical reflectivecomponent comprising at least one inlet channel or port adapted to allowgas to enter the at least one sensor and at least one outlet channel orport adapted to allow gas to exit the at least one sensor and areflective interior surface adapted to reflect and direct light from thelight source to the surface coated in fluorescent dye and/or lightreflected from the surface coated in fluorescent dye to the photodiode,and a pressure tap being the inlet channel or the outlet channel andbeing adapted to allow for measurement of gas pressure within thesensor, the surface coated in fluorescent dye comprising a plurality ofstructures protruding from the surface toward the light source and beingadapted to increase surface area coated in fluorescent dye; and aprocessor adapted to receive the signal, the processor comprising analgorithm with an output, the output comprising a blood oxygenconcentration response (SpO₂ Response) value corresponding to a realtime measurement of changes in the subject's blood oxygen concentrationmeasured based at least in part on the signal, wherein the processor andalgorithm are further adapted to produce the output and generating acontinuous blood oxygen concentration profile for the subject over time.2. The breathing mask sensor system of claim 1, wherein the surfacecoated in fluorescent dye is a modular component adapted to be removedand replaced to extend life of the sensor by replacing the modularcomponent without discarding the sensor as a whole.
 3. The breathingmask sensor system of claim 1, wherein the at least one sensor isadapted to obtain at least 50 meaningful samples per second.
 4. Thebreathing mask sensor system of claim 1, further comprising atemperature controller adapted to maintain both the gas being measuredand the sensor at a substantially similar temperature to preventcondensation from forming on the elements of the sensor and thusadapting the sensor to operate accurately in environments comprising 50%humidity or greater.
 5. The breathing mask sensor system of claim 4,wherein the at least one sensor is externally mounted to the breathingmask.
 6. The breathing mask sensor system of claim 4, wherein the atleast one sensor is in a sensor chamber within the breathing mask.
 7. Abreathing mask sensor system for identifying or predicting dangeroushealth conditions comprising: a breathing mask; at least one firstsensor and at least one second sensor each being subject-mounted, thefirst sensor adapted to measure partial pressure of oxygen within themask in real time and to produce a signal corresponding to said partialpressure of oxygen, the first sensor comprising a light source, a glasslongpass filter, a surface coated in fluorescent dye, a photodiode, afrustoconical reflective component comprising at least one inlet channelor port adapted to allow gas to enter the at least one sensor and atleast one outlet channel or port adapted to allow gas to exit the atleast one first sensor and a reflective interior surface adapted toreflect and direct light from the light source to the surface coated influorescent dye and/or light reflected from the surface coated influorescent dye to the photodiode, and a pressure tap being the inletchannel or the outlet channel and being adapted to allow for measurementof gas pressure within the first sensor, the surface coated influorescent dye comprising a plurality of structures protruding from thesurface toward the light source and being adapted to increase surfacearea coated in fluorescent dye, the second sensor adapted tosubstantially continuously measure flow rates of gas within the mask andto produce a signal corresponding to said flow rates; and a processoradapted to receive the signal, the processor comprising at least onefirst algorithm with a first output, the first output comprising a bloodoxygen concentration response (SpO₂ Response) value corresponding to areal time measurement of changes in the subject's blood oxygenconcentration measured based at least in part on the signal of the firstsensor; the at least one first algorithm or a second algorithm with asecond output, the second output comprising a hypoxic ventilatoryresponse (HVR) value corresponding to ventilation of the subject asaffected by blood oxygen concentration based at least in part on thesignal of the second sensor, wherein the processor and algorithm(s) arefurther adapted to produce the first and/or second outputs and togenerate a continuous blood oxygen concentration profile and acontinuous hypoxic ventilator response for the subject over time.
 8. Thebreathing mask sensor system of claim 7, wherein the surface coated influorescent dye is a modular component adapted to be removed andreplaced to extend life of the sensor by replacing the modular componentwithout discarding the sensor as a whole.
 9. The breathing mask sensorsystem of claim 8, wherein the at least one sensor is externally mountedto an existing breathing mask.
 10. The breathing mask sensor system ofclaim 7, wherein the at least one sensor is adapted to obtain at least50 meaningful samples per second.
 11. The breathing mask sensor systemof claim 7, further comprising a temperature controller adapted tomaintain both the gas being measured and the sensor at a substantiallysimilar temperature to prevent condensation from forming on the elementsof the sensor and thus adapting the sensor to operate accurately inenvironments comprising 50% humidity or greater.
 12. The breathing masksensor system of claim 11, wherein the breathing mask system comprisesan integrated mask wherein the at least one sensor is in a sensorchamber within the mask.
 13. A method of identifying or predictingdangerous health conditions comprising steps of: providing a breathingmask sensor system adapted to detect or predict dangerous breathing orother health conditions, the sensor system comprising, a breathing mask;at least one subject-mounted sensor, the sensor adapted to measurepartial pressure of oxygen within the mask in real time and to produce asignal corresponding to said partial pressure of oxygen, the sensorcomprising a light source, a glass longpass filter, a surface coated influorescent dye, a photodiode, a frustoconical reflective componentcomprising at least one inlet channel or port adapted to allow gas toenter the at least one sensor and at least one outlet channel or portadapted to allow gas to exit the at least one sensor and a reflectiveinterior surface adapted to reflect and direct light from the lightsource to the surface coated in fluorescent dye and/or light reflectedfrom the surface coated in fluorescent dye to the photodiode, and apressure tap being the inlet channel or the outlet channel and beingadapted to allow for measurement of gas pressure within the sensor, thesurface coated in fluorescent dye comprising a plurality of structuresprotruding from the surface toward the light source and being adapted toincrease surface area coated in fluorescent dye; and at least oneelectronic component, including at least a processor, the at least oneelectronic component adapted to receive the signals, the processorfurther comprising an algorithm; calculating with the processor toproduce and algorithm an output comprising a blood oxygen concentrationresponse (SpO₂ Response) value corresponding to a real-time measurementof changes in the subject's blood oxygen concentration measured based atleast in part on the signal; generating, with the processor andalgorithm, a continuous blood oxygenation profile for the subject overtime; and identifying or predicting dangerous breathing or other healthconditions of the subject based at least in part on the continuous bloodoxygenation profile for the subject.
 14. The method of claim 13, whereinthe sensor further comprises a temperature controller adapted tomaintain both the gas being measured and the sensor at a substantiallysimilar temperature to prevent condensation from forming on the elementsof the sensor and thus adapting the sensor to operate accurately inenvironments comprising 50% humidity or greater.
 15. The method of claim13, wherein the surface coated in fluorescent dye is a modular componentadapted to be removed and replaced to extend life of the sensor byreplacing the modular component without discarding the sensor as awhole.
 16. The method of claim 13, wherein the at least one sensor isadapted to obtain at least 50 meaningful samples per second.
 17. Themethod of claim 13, further comprising the step of continuouslycalibrating the sensors during use based on changes in the measuredambient barometric pressure.